Have you considered a Watts Brothers Tool Works floating chuck drill? Truly
amazing tool for boring square, hexagonal and octagonal holes. 'Tain't
cheap but fun to watch.

--
Glenn Ashmore

I'm building a 45' cutter in strip/composite. Watch my progress (or lack
there of) at: http://www.rutuonline.com
Shameless Commercial Division: http://www.spade-anchor-us.com

"Dan Miller" wrote in message
...
I need to make a slot with square ends in a steel bar (0.25" wide and
about 0.5" long). I'm thinking of using a 2 flute end mill and then
sqaring up the corners with a file but wonder if there is a more precise
way do do this with a broach or something? Any suggestions?

Thanks

Dan Miller
Seattle WA.