Does anyone make files or rasps with a smooth side. Looking for a rat tail or round file with a flat spot. aka about 3/4 round in different diameters.

Do i have to make my own?

I think that is something you'll have to make, yourself. Such is the case with gunsmith tools at times. Make it to suit your needs. I love my Dastra chisels and gouges, but I'm glad I've had "extras" to alter to suit my needs. I had always thought I'd have a use for a short, round 'rasp' of sorts, to use roughing in the barrel channel to put me closer to 'scraper distance'. I ended up annealing a 16" rat tail file and cutting into useful sections, drilling and tapping a center hole to fit an off-set handle, and then re-hardening. Works good for me, and saves me some time. Dastra used to offer a round 'rasp' that had hand stitched 'teeth' and was threaded for an off-set handle, but that was discontinued long ago.

i haven't bought one.. just sanded a side done on my disc/belt combo sander -- don't get it hot

I just jump on the 2-1/2" belt grinder and make a flat or safe side. Takes about 2 minutes.

gonna flatten a chainsaw file. $9 for 2