Im guessing he has one of the first gen bolt stops that are solid not hollowed out like the other pictures that are on here. So it will be fine when he gets it all filed down. I did mine with a dremel with cut off disc and a bench grinder. Go slow and be carefull with the dremel cutoff discs. Finish it off with a fine file and you should be left with a nice part.
Yeah, well, about that....
Guessing isn't going to do him any good, unless he ups the ante a bit and provides a bit more info.
If it really is an $80 part, which seems like a right bloody rip-off, then the smart money is on making a new one from scratch and selling the old one on the EE, though it's a little late now it's been molested.
If it is solid, he has at least a chance of pulling it off with some careful work with a cut-off wheel.
Otherwise, it's a hacksaw and file job. And a drill press, with regular old drill bits. And a buck or two worth of wet or dry sandpaper to do the finish work with. A couple wraps around a Popsicle stick makes a dandy fine file for that sort of work.
I will casually suggest that a new file be bought, as the old one is like to be thoroughly buggered.
If a fella really wanted to be flash, then spring for some Starrett flat stock of the correct thickness, and of a known material medium or high carbon steel, which can be hardened fairly simply. Once hardened, polish the part up and apply heat slowly until the color changes to a nice yellow or blue. Lots of videos on youtube. Some even with worthwhile info in them!
A stroke of the file is a pretty standard shop practice to test how hard a material is, and thus, whether the tools will cut it easily or not. But you need to be observant of what exactly is happening when you do try the file, to understand what is going on.
I like files, great tools, but generally mistreated and misunderstood.
Cheers
Trev