12-07-2014, 07:37 PM
Will do David!
I'm actually enjoying this challenge, very much. BTW, I need to get a set of good reamers. I didn't have a Ø.125" reamer for those two holes, so I used high quality 1/8" drill. Checking with the shank of a carbide end mill which measured (with my Mitutoyo 293-344 digital electronic micrometer) right at 0.12495, and it was a very snug fit. Perfect size!
I used a 6mm carbide end mill to rough out the slot, leaving about .001" per wall for the finishing end mill. For that I used a 3/32" (.09375") two-flute solid carbide end mill, and crept up of the final .251" width. It may be just a touch snug on that dimension, though a 0.2500" spotting drill shank slid up & down smoothly. I used a smooth face "safety edge" file to get the corners sharper, though may want to touch them up again before I ship the parts out.
I'm actually enjoying this challenge, very much. BTW, I need to get a set of good reamers. I didn't have a Ø.125" reamer for those two holes, so I used high quality 1/8" drill. Checking with the shank of a carbide end mill which measured (with my Mitutoyo 293-344 digital electronic micrometer) right at 0.12495, and it was a very snug fit. Perfect size!
I used a 6mm carbide end mill to rough out the slot, leaving about .001" per wall for the finishing end mill. For that I used a 3/32" (.09375") two-flute solid carbide end mill, and crept up of the final .251" width. It may be just a touch snug on that dimension, though a 0.2500" spotting drill shank slid up & down smoothly. I used a smooth face "safety edge" file to get the corners sharper, though may want to touch them up again before I ship the parts out.