Of all the tools I got....

[PixMan]

Tonight's progress, got the 1/2" square drive done using a 1/8" four flute solid carbide (uncoated) Bassett double ended end mill. I was afraid to do this with the end mill being just barely long enough to get through the piece because I thought for sure it would break in the corners.

Running it at 3300 rpm and 1.5 inches per minute, I took three depth cuts of only .015" width and about .090 deep. Starting with a hole drilled using a 12mm (0.4724") through, the first climb milling cuts into the corners were scary but the end mill never dug in nor squealed in protest. It cut like butter! At the programmed size of .500", it actually came out at .494" square. I reprogrammed to .510 and cut the finish pass to .003 (versus .010), the square finished at .505".




I had measured several 1/2" drive extensions and a Crapsman ratchet, across the rounded off corners of the fairly new tools measured less than the distance of my milled square socket, so I didn't have to file the corners to a sharper square. Nice!

Making pins tomorrow and pressing them in. Them the final test fit. I'll let you know how it goes.