Airburst

I've got an old Raleigh front fork with front fork-ends designed for a very thin (7mm?) axle. According to Sheldon, these can be filed out to admit a thicker axle on a more modern wheel, which is what I'm planning to do with mine. As they're sort of forward-opening, I plan to do the filing on the lower half of each one, as it should be under less stress and I'll know I've done it symmetrically when the axle just fits into each one. The main question I have is, how anal do I have to be about not leaving any sharp corners? I'm worried about creating some sort of stress concentration which causes the whole thing to snap in half and put me on my face. It's a mild steel fork. Am I being paranoid here?


Thanks in advance.