Thinning windshield wiper inserts for bogota material.

[Drifty Flintlock]

I've made bogotas out of the wider windshield wiper blades before. The tip works reasonably well, but the wrench end is too wide. I've done some ugly things like filing, tapering, etc. It works, but like I said, it's ugly as sin.

Street sweeper bristles aren't something I've been able to find where I live. So I've been trying to figure out how to take a .160" windshield wiper insert and quickly and consistently turn it into .125", give or take. This has proved astonishingly diffcult. Here are the things I've tried which have failed.

Grinding wheel (inaccurate)
Hand filing (inconsistent)
Hand filing between two vices (metal flexing)
End mill (inconsistent)
End mill with jig (metal flexing)
Coarse sandpaper (too slow)

Now admittedly... I'm not exactly a born craftsman. But still. I'm about at the end of my rope here. There has to be a better way. How can I do this, or is there something else I can use that's easily obtainable?

[mjwhit]

Im a fan of a belt sander for removing thickness.

[kwoswalt99-]

Street sweeper bristles aren't something I've been able to find where I live. So I've been trying to figure out how to take a .160" windshield wiper insert and quickly and consistently turn it into .125", give or take. This has proved astonishingly difficult. Here are the things I've tried which have failed.

Are those measurements correct? Because if they are, I'm not sure what we're talking about.

[PowerHaus930]

I think he is talking about the width of the metal not the thickness.

[Bobnsteele]

My time in a machine shop says surface grinder. $$$$$
My hobby in knife making says a 42x1 or bigger belt sander/grinder $$$ its like having a power file.
Or look for different raw materials $

[Latestplague[]]

Belt sander. Or use a 12inch 2nd cut mill file and alternate 10 swipes each side til your close. Then go to polishing/grinding rotary stones and sandpaper . The 2nd cut doesn't cut overly aggressive but takes enough off to not be slow

[Drifty Flintlock]

Right, it's the width that's the issue, not the thickness.

Belt sander sounds like a good idea, I'll see what I can do.

[Jacob Morgan]

I've been using a 1" x 42" Kalamazoo belt sander for a few years, couldn't be happier with it. Plenty of power and can change belts quickly. A really coarse belt takes off the material quick. Being able to put on a fine belt means little or no hand finishing. Can sand wood, steel, and non-ferrous. Has a flat platen for flat grinding. Don't skimp on cheap belts, use good name brand belts, it makes a difference.

Only thing it doesn't do well are smooth, tight inside curves--I use a stone wheel in a Foredom tool for those.

Great for sharpening wood chisels and knives too. I have a very good abrasive wheel grinder, but do not use it much.