One of the more challenging aspects of the dual element mod is the cutting slots in the ceramic caps that hold the original heating element that in order to route the wires to the added element. I have discovered an inexpensive ($3 - $4) tool that makes this an easy five minute or so process. The Stanley Carbide grit rod saw, Stanley part number 15-410. The rod saw is designed to be used as a blade in a hacksaw frame. I just hand held the rod saw when I tested my idea on a couple of spare heating element holders. Sure beat the heck out of the Dremel and carbide cutter that I used to do my own dual element mod.
Hope this will make your mod easier to perform.
Anything to make it easier ;) I did mine with a dremel tool and still took a while.
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I just used a rattail file, and it didn't take very long.
I too tried using a file. I wasn't too happy with the progress I made and resorted to the Dremel. The rod saw was way faster.
i used a die grinder with a carbide bit for grinding aluminum they are coarser than the steel ones and burned through it in no time