This conversation has been merged. Please reference the main conversation: Can I use a hand-held knife sharpener to sharpen the mower blade?
Tired of the weak and thin blade that needs constant sharpening. Forged a new blade from a Honda mulching blade set. Took quite a bit of work, but I now have a twin blade that fits perfectly without risk of damaging the mower. The performing heights are identical to the OEM blade, and the weight is not much more than the factory blade.
The performance is fantastic. A bit of physics here. 1. The blade is a "tad" heavier, so the spin up time is a bit more of a strain on the battery, but the heavier an object in motion, the harder it is to stop. So once it is up to speed, usually within 1 second of the factory blade, it stays up to speed and has a much better cut. The mower doesn't bog down due to the centrifical force. It also doesn't affect the auto brake.
This wasn't a project for most DIY, I did it at a machine shop with help from a pro. I'll post pictures later. This mower is fantastic, but the weak spot is the weak blade. Note that the reason for the small metal OEM blade is for weight, battery life and load on the battery and motor. DO NOT deviate much from the OEM blade weight.