Thanks for the replies.
The edges came bent already (it's a cover for an aluminum enclosure). I agree with sandwiching and I'm thinking I'll bolt down the first sheet of wood, use the mill to cut an appropriate-sized groove for the edges of the cover, then sandwich the cover and another piece of wood.
I figure I can always stop the process a couple times to move a couple clamps.
Now, the puzzler -- why specifically a step drill. I don't use those often, so I don't have one handy but IIRC there is not spiral flute that would try to pull the aluminum upwards. Is this why?
Also, ckirchen, why a spiral flute EM? Wouldn't the straight flute EM be better or will there be a problem with clearing out the chips once the wood sheet is over it?
Cheers,
-Neil |