A huge challenge for me was to restore the BIGGEST Rasp in the world with a few hand tools. I have never seen such a big rasp and so heavy. The rasp is produced in the USA, 1878 was registered trademark Western files. It is hard to know when it was produced exactly but it is definitely very old. 

The biggest rasp in the world Restoration
The biggest rasp in the world – 28″

About the biggest rasp in the world!

After taking measures I was speechless. 28” (71 cm) is long including the handle and 24” (61 cm) the rasp itself. It weighs 64,40 oz or 1827 g. Also I can see that this rasp is hand crafted from quality steel.

The rasp is generally in good condition with absence of surface rust. The handle looks worn and dirty as well as an aluminium ring. It looks like someone replaced the handle recently, maybe in the past 10-20 years.

In the video below you can enjoy watching how I hand restored the biggest rasp in the world!

Advertising material for the Great Western Files is without the handles and this indicates that the factory sold only files and rasps without the handles. If you are lucky to find one, they probably will have a different handle from the other or none. 

After extensive research I haven’t found one single information about the rasp in this size and I really wonder why it is so big? Who could use it and for what? Was the rasp a commercial item to be displayed. If you have any info, please let me know! Furthermore, It would be great help to understand more about this huge rasp. 

The Restoration Process

I started by removing the handle from the rasp. The handle fell out after a few hits with the wooden mallet. So, I was able to remove the aluminium ring from the wooden handle and started removing loose rust from the rasp. To remove deeper rust I submerged the rasp in 35% vinegar overnight. That did the trick perfectly as always.

Removing rust.
Removing rust.

I cleaned the rasp quite well with a steel brush. Took me a while by hand but I was very pleased with the result. To protect the metal surface, I applied the thin layer of machine oil. As a result, that gave a nice and rich reflection.

Applying machine oil to the rasp.
Applying machine oil to protect the surface from further rust.

After that I sanded the handle and the aluminium ring with 120 grit and 180 afterwards. Polished on my hand crank grinder. I wanted to give a character to the wooden handle because it is plain. So, I made two new wooden handles for pyrography to burn four rings. Attached the bits and heated them with a torch burner.  

Burning the rings on the handle.
Burning the rings on the handle.

Beside burning four rings on the handle I made a circular brass ¨coin¨ and stamped FFD on it. Then I glued it at the end of the handle. In addition to protect the wood I applied a layer of teak oil, paraffin oil and homemade beeswax polish. Wow, the look of the handle was amazing. Finally I joined the handle and the rasp with a rubber mallet.

The handle after applying teak oil, paraffin oil and and homemade beeswax polish.
The handle after applying teak oil, paraffin oil and and homemade beeswax polish.

The result after restoration

FFD detail on the handle.
FFD detail on the handle.
The stamp detail after restoration.
The stamp detail after restoration.

Please subscribe to my YouTube channel if you want to see more of my upcoming restoration projects! Also DON’T FORGET TO CHECK OUT LADIES Pocket Knife | MINIATURE Folding Knife Restoration Video: https://youtu.be/Is5pmUElkOc

The biggest rasp made by hand and restored by hand.
Made by hand and restored by hand.

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82 Comments

  1. Such an awesome screw driver. Have we seen that before? I was impressed also with the woodburning handmade tools. Look at you go Boris. I love how your expanding your imagination and videos in this new shop.

  2. that’s just impressively big!! geeze. now your video did leave me with some questions however: at 4:04, is that an abrasive pad you are using to clean the file teeth? and how well does it work at the end! I would’ve liked to see you cutting some metal or wood with it 😉

  3. I nearly didn’t watch this video because of the intro music. I was just going to turn it off and it stopped.

  4. Looks like a bodywork file in the automotive sector to me, for filing large areas on chassis with body filler. No rasp for wood.

  5. Awesome work Sir, and your biceps are looking great. 💕
    Best part : we have a problem 🤗😃

  6. Nice job! That thing is massive. Never seen a rasp so big. OMG. I also really like the editing in this one. It’s very smooth.

  7. Nice job! That thing is massive. Never seen a rasp so big. OMG. I also really like the editing in this one. It’s very smooth.

  8. Great job and well done great things about you are amazing restores look beautiful and new

  9. Great job and well done great things about you are amazing restores look beautiful and new

  10. Mächtiges Teil. Wahnsinn. Und mal wieder eine wunderschöne, tiefenentpannende Restauration.

  11. Mächtiges Teil. Wahnsinn. Und mal wieder eine wunderschöne, tiefenentpannende Restauration.

  12. I fell asleep halfway through the video last night. Started watching again from the beginning and still amazed by your work. And to go with no electricity even with pyrography. I just have no words to describe how amazing your putting your effort in it. Great job once again, Boris. Thank you for another piece of calming entertainment. Stay safe 😄😄

  13. I fell asleep halfway through the video last night. Started watching again from the beginning and still amazed by your work. And to go with no electricity even with pyrography. I just have no words to describe how amazing your putting your effort in it. Great job once again, Boris. Thank you for another piece of calming entertainment. Stay safe 😄😄

  14. Wow that thing is really big! It must have either been made for Giants or for display. I think the trick you showed for the vinegar when a part doesn’t fit in your bin was great! 👍👍

  15. Wow that thing is really big! It must have either been made for Giants or for display. I think the trick you showed for the vinegar when a part doesn’t fit in your bin was great! 👍👍

  16. Having restored files and rasps, I gave this a small thought and believe it to be a harriers rasp for smoothing the nails on horses hooves. Long because the operator has raised the hoof and placed it between his legs and now giving it a go with long strokes. Be well my friend.

  17. Great work. Plus great editing!
    Do I want to see the knife you are going to restore with this rasp 😉

  18. É uma lima dessas que falta na minha oficina. Um ótimo trabalho. Parabéns 👏🇧🇷👏

  19. Super restoration with some final touches…
    But if it is oil on the rasp it will clog up very fast…
    For preservation of files use only white choke…
    Greetings from Serbia

  20. Приветище мой друг Борис👋👋👋 работа по реставрация большого рашпиля и доработка дивная, ценю и уважаю твои труды🤝 будь здоров и береги себя ✌🏻🇷🇺

  21. Having restored files and rasps, I gave this a small thought and believe it to be a harriers rasp for smoothing the nails on horses hooves. Long because the operator has raised the hoof and placed it between his legs and now giving it a go with long strokes. Be well my friend.

  22. Great work. Plus great editing!
    Do I want to see the knife you are going to restore with this rasp 😉

  23. É uma lima dessas que falta na minha oficina. Um ótimo trabalho. Parabéns 👏🇧🇷👏

  24. Super restoration with some final touches…
    But if it is oil on the rasp it will clog up very fast…
    For preservation of files use only white choke…
    Greetings from Serbia

  25. Приветище мой друг Борис👋👋👋 работа по реставрация большого рашпиля и доработка дивная, ценю и уважаю твои труды🤝 будь здоров и береги себя ✌🏻🇷🇺

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