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[kgtiger]

Sounds like you need to toughen up princess, just pull a few more 12 hour days to get use to it?

I would just cut all edges square with the RZ and just round them with a hand file.
Try a, Flat Bastard to remove most of the waste and a, Flat Second Cut to clean the rough edges.
You could use a, Flat Smooth to clean up the edges, however as it very fine, you will find that the Ali clogs the file.
If/when this happens, just use a wire brush to clean it up.

To get a overall smooth edge, with out tool marks. Just use the flat second cut file, by, Draw Filing it along the edge.
Just look at the bottom of this page if your not sure,http://autospeed.com/cms/title_Using...5/article.html

Good luck mate.