On 2009-01-21, Buerste wrote:

[ ... ]

I've never had to cut "T" slots but the thought scares me. Is that
operation as hairy as it appears to be to me? Or, just another irrational
fear?

I had no problem the one time which I have cut a T-slot -- and
it was a circular T-slot at that.

I started with a two-flute end mill and cut the circular slot to
the desired depth, along with a short radial slot for entry, then
mounted the T-slot cutter, cut in from the edge to the proper radius and
around the workpiece following the original circular milled slot. I
used a small rotary table for workholding and motion for both
operations.

And all of this was done on an ancient horizontal mill -- which
actually helped clear chips somewhat compared to a vertical mill.

The main trick with the T-slot cutter is keeping a shop vac
close to it to pull out chips so they don't clog the slot as you form
it.

Enjoy,
DoN.

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