Chris M wrote:
 though). Soldering iron tips are made of copper, so I
 don't see any reason why I couldn't chisel one down
 for a specific task. Any thoughts? Am I courting
 disaster? 
Depends on the tip. The better soldering tips are coated/plated with another
metal, and filing removes that coating. It will still work, but will also
require more maintenance to keep the tip working properly.