On 2012-03-16, Tim Wescott wrote:
On Thu, 15 Mar 2012 12:10:40 -0600, Pete C. wrote:

[ ... ]

I'm having a little difficulty picturing exactly what you're trying to
do. Perhaps drill and broach? You can make your own broach a bit more
easily than the ECM and EDM lines of thought. Come to think of it,
perhaps rotary broaching might do what you need.

I didn't know that rotary broaching existed. It doesn't look like it
makes the surface finish that I'm interested in (and I was kinda looking
for home-shop sorts of solutions) but it does look like it'd work well.

Isn't there a process that uses a diagonal bit in some perverted fixture
that makes it cut square holes?

There is a triangular bit with a floppy shank in a guiding
holder which cuts square holes. Not sure how deep it will go, or how
thick your workpiece is. If the workpiece is too thin, I would expect
warping.

Good Luck,
DoN.

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