In article ,
Dan Miller wrote:
Great, thanks for all of the suggestions. I'll give it a try. the slot
is through so that should simplify things. I'll mill with a two flute
cutter first and square up the ends with a 0.25" bit. Problem will be
holding the bit but I think I can drill a hole in a piece of drill rod
and set a 0.25 bit at a 45 degree angle to the rod with a set screw
inserted along the axis to hold it in place. That way the tip can reach
the far side of the slot without the holder having to enter. I guess the
other option is to use a bit holder that will fit in the slot, mount the
bit perpendicular to the bar, and scrape one corner at a time with say a
0.125 bit. The slot dimensions are 0.25 wide by 0.5 long through a 5/8
round bar.

How deep is your slot? Why not mount the 1/4" bit end on, and
just grind enough of a rake on the end to let it cut well as you crank
it in? No real need for your proposed 45 degree slot.

Good Luck
DoN.

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