I'm sorry I didn't see your question sooner. Please forgive me for not answering sooner. I shape most of my guards, thin or not, about the first 90% with a Fordon hand tool and then the last 10 % with files and sandpaper. Even this thin the gard seems really strong.Question on the guard. How did you get that lower finger section so thin? Was that hand filing/shaping or mechanical with a grinder or rotary? I've always been hesitant on making them thin like that but would like to try.
Maybe this? https://usaknifemaker.com/1-6-hp-sr-motor-and-fct-foot-control-speed-control.htmlWhat is the Fordon hand tool. Not one I know of but whatever it is it has helped in the making of a very nice piece of working art.
Thanks Tim. Now that I see it, I have heard of the tool and how much better it is than the common dremmel