One can sand or grind the edges to dull them, but on very thin materials that's not enough. Many of the chastity belt makers of today (UK and China mostly) make silicone sleeves that cover both edges and one face of the metal to provide protection from sharp edges. Wearing the belt daily for the long term wears out the silicone and if you're not diligent about inspecting it eventually the sharp edges of the metal will appear once again.
The metalworking solution to the problem is to roll, or fold the edge back on itself so the new edge is a rounded edge or at least a fold. I'll show how to do rolled edges another time but today I'll show how to fold an edge really easy. There are many things you can use, the easiest being a metal brake. You can make one yourself, or buy one, or possibly borrow one at a machine shop or HVAC company. In lieu of that, you can fold it yourself by hand with a very simple tool - a "folding tool". It's two stamped pieces of steel welded together about the right thickness for folding thinner materials such as aluminum, mild and galvanized steel, and stainless steel. Many places sell them well below $20:
Home Depot: http://www.homedepot.com/p/Unbranded-12 ... qaE2OKDr6c
Amazon: http://www.homedepot.com/p/Unbranded-12 ... qaE2OKDr6c
Here's the one I purchased at Home Depot this morning:
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I cut out the 5" wide belt using my old table saw that I have a carbide-tipped blade installed. There is a problem with cutting thin metal of any kind on a table saw - it's very easy for the edge running along the fence to "bite" between the fence and the top of the table. I thwarted that by plopping a thin flat (aluminum in this case) next to the fence for the metal I'm cutting to ride on, thus the edge hits the fence and not the seam between the fence and the table.
Powered up and fed nice and slow, wearing thick rubber coated kevlar gloves to prevent finger cuts (or worse), and a full face shield to protect my face. Feed nice and slow, and I got a very nice cut indeed. You can see the steel I cut off on the right of the fence, the aluminum flat on the left of the fence.
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I then repeated for the next 30 degrees, then 90, then 120, then almost 180. You can't get it totally flat with the tool and that's good, you'll be left with a nicely rounded edge.
Repeat the process for the unfolded side, and you should end up with this:
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I used a piece of galvanized steel for this demonstration just because I had some laying around but this method works with stainless too. The bends will generally be crisper with stainless.
When I'm ready to flatten this, I'll be using a pair of steel rollers where the bottom roller is fixed and the top roller is adjustable with a threaded knob above it. Before I feed it through, I'll be applying adhesive long the inside edge so that the edge lays flat. Once that is flattened and cures, I'll swab on some silicone sealant along the edge to insure the edge is completely safe. You can also install the belt on the person so that the folds face out rather than against their skin, just to be sure.
