Carton 100mm f/13 "MD" OTA Construction - Outer Edges of Baffles being Smoothed
 

All four baffles held in vise to smooth out their outer edges. (Click to see an enlarged image.)

 
With the three baffles mounted in a bench vise, stacked I was able to use a file to smooth their outer edges all at once after they were cut with a hole saw on my drill press. This eliminated the burrs, which significantly reduced the chance of lacerations. It also aids in forming a more uniform seal between the baffles and the ProtoStar flocking material surrounding the interior of the tube. For airflow, I will be cutting small notches around the outer edges of each baffle, but the notches in one baffle will not align with the next one in line. You will see this done later in the build.