fsciorelli:

Well, they make hobby saws that have the teeth all jagged one way, called a 'flush-cut saw'. I was tempted to get one from Lee Valley. Another option would be to use a dremel cutting wheel or blade to get it close, then use the edge of one of the cutting disks, or even one of the router bits, to file it down flush. Yet another is that Dremel makes that new cutter that vibrates back and forth, like hedge trimmers do, but with only one blade, now scissors-like on clippers.

It all depends on how close ya can get, what tool(s) you might already have, and which ones you might want to buy as you'll use 'em again later...

Mebbe a pic of the offending 'mounting boss' in question might help?

If its the 'molded-in' standoffs on the chassis bottom for mounting the gearboxes, I'd say Dremel (or similar) rotary tool w/ a cutting disk/blade to get close, then use it like a file to smooth it down.


Hope that helps ya out.