Next, place the part in the milling machine vice using the line on the end, just
made, to assist in positioning it, reduce the thickness to 15mm, Photograph 9. The
viewer may be puzzled by the lack of machining lines, actually, I had removed the
part from the vice and found it very marginally thicker at one end to the other.
As a result, I placed a file in the vice and rubbed the cutter holder on this applying
more pressure at one end to correct the error. Having done that, I realised I had
not taken the photograph, hence the lack of machining lines. The photograph also
clearly shows the complexity of the part that has been produced relatively easily.
Except for shaping the ends, all that is required is to drill the three holes for
the cutters, Photograph 10, and the tapped cutter fixing hole.
Measure the thickness of the cutter holder between the flat and curved surface and
from this determine the necessary thickness of the gib strip (4). Cut a slice from
the piece of material prepared for this and mount it in the vice, similarly to photograph
9, and machine to the required thickness. Having done that, lightly file a small
portion away from the corner that will eventually have the cut out C made. The purpose
of this is to ensure that the gib strip is assembled the same way round for the remaining
operations until at such time as the cut out is made.
Assemble, body, cutter holder and gib strip (correct way round), again using a grub
screw in the M6 thread to ensure alignment and fit one M4 grub to secure the parts.
Drill through the other tapped hole to establish the position of the first hole in
the gib strip. Use the same size of drill that you used for tapping the hole. Fit
and secure second grub screw removing the first and mark the position of the second
hole. Remove the gib strip and drill the two 4.1mm diameter holes 3mm deep.
Place the body in the three jaw and make the shank to your preferred size, Photograph
11. With the shank now made, the head together with the cutter holder and gib strip
can be machined to produce the final shape of these parts as shown in Photograph
12. This photograph clearly shows the need for the corner of the gib strip to be
cut away to make it possible to fit the dial. It is hardly worth setting up the milling
machine for this being more a task for the small hack saw and file.