@NotaGuntuber@Daniel00Higgins Yeah id say thats probably the way to go, even small long reach endmills can only go so far. Its doable, but not without an extra setup from the opposite side and more than one cutter. There was likely a better answer to how I did my own monocore here, but it took a long time.
@NotaGuntuber@Daniel00Higgins The other thing to consider is the radius is partially giving it strength and is much easier on tooling than a 90° its always a trade off, but a 1/16th may as well be a mile. Alot of times 90° square corners in fixturing means no corner at all, theyre always removed.
@NotaGuntuber@Daniel00Higgins That or Alternatively drill the corners out within the allowed tolerance and then "broach" to the corners since endmills would have a hard time with it, but I think that also means two setups rather than one either way
@NotaGuntuber Well that would beat a giant wedge broach by miles, gives me some ideas now that its not a blind hole. Makes me think if only a button insert or round turning insert could just be used to take out a thou or two at a time but I suppose its the same principle here.
@NotaGuntuber Yeah, then high speed steel sticking out of a bar is the best bet, theyre also not terribly hard to "make" but sometimes it is easier/cheaper to buy. Heat treating reliably with a small oven is a pain.