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nut files are a necessary part of the job and if you're not going to use them you shouldn't expect good results; any success people have with their homemade tools is miraculous in my opinion. there's too many factors determining whether the slot will work without buzzing or binding to trust the job to some piece of scrap metal with sandpaper glued onto it.
no one wants to buy the files if they can help it, a single person has yet to chime in and claim that they enjoy dropping $60 whenever they can, but they cost that much because they're good quality tools. if you're making a new nut from a blank, which it seems you are; why go through all the trouble of sanding and shaping just to wind up putting shoddy slots into it that'll probably drive you to replace the nut again? if you're going to make a new nut, may as well get it perfect the first time so that you never have to carve another.
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