"Gunner" wrote in message
...


As the diamond plate "diamonds" stand proud..I finished up the gage
holes using a big face mill and put in a slight counter bore so the
gauges sit flat on a machined surface. Actually looks pretty good, but
took a lot of steps to do something that should be pretty simple.

Did you consider doing the cutting from the "back" side?

It's a lot flatter there and, while the "points" might need touching up with
a file/rotary rasp/sanding drum, the rest of the circle would be a simple
cut.

You might also want to consider a circle guide for a router or Dremel - HSS
bits or, for the router, hole saw bits can cut AL with few problems and
could also simplify the task of creating the border for the bezel.

BTW, do you have a rotating table and a vertical mill? grin