Hi All,
Just wanted to post back with results so in case anyone in the future looks for the same information, there'd be some references recorded.
The whole job took about 45 minutes for the two carriers. It started out slow and as I got the hang of the process it went a lot faster.
1. I took the necessary tools as it was suggested by Ned above (thanks!!!) from my local DIY store. It cost less than $10 in total for the Metal file and the 600 grit sand paper. I also prepared the two carriers to be filed out. As I mostly shoot 135 and 6x6 I bought spare carriers for these, just in case I mess up the job I could still print with the originals. It all worked out though so spares were not necessary.
2. I prepared a small box with a plastic bag in it to hold the fine dust that comes off the carrier. This was mostly not to set off an alarm in my wife's head.
3. I marked a rough guide as to how far I want to go with the filing with a permanent marker.
4. As I had no vice I had to hold the carrier in my other hand while filing away. It felt awkward at first but got the hang of it quick. In order not to bend the carrier I was only pushing the file and never pulled on it. This kept the two sides of the carrier constantly pushed together.
5. This shows one side already filed out nicely.
6. And with both sides filed.
7. I then took the 600 grit sand paper and made sure the edges were sanded until they were completely smooth. I especially paid attention to the side where the negative comes in contact with the carrier.
8. Here you see the fine dust that was the result of my filing.
9. I then ran a Q-tip along the edges and made sure no fibers were caught from the cotton tip by some leftover burrs. (Thanks Dan for the tip!)
10. For testing I placed some negatives in the carrier I didn't really care for. This one had a light leak so the top and bottom edges of the frame can't be easily seen but if you look carefully you'll see all 4 sides show some extra film beyond the photo which is what I was after.
11. The same with the smaller 135 carrier.
12. The last step was to color the exposed metallic edges black to eliminate the unnecessary reflections. As I had no model paint or anything else, I went for a permanent marker and it worked remarkably well. It was a bit of a hassle to apply and I am not sure how "permanent" it'll end up being. If you can - do this with some model or gun pain instead.
If any questions just fire away!
Cheers,
Ben