I've got about zero experience with steel in a mill, I've been limited to aluminum and various plastics so far. You guys make it sound easy, but I'm not convinced that I can get it right the first time. If I snap a tap off, I don't have the tools needed to extract it.
Hu- I am planning on bolting it to an 80/20 extrusion.
Hardmill- I greatly appreciate the offer. If you were closer I'd be on your doorstep with a case of Henry's.
WMS- Thank you very much for your testing- I am convinced that it is possible, but am not sure I can convince a local shop to help me.
I did come up with a simpler alternative (for a price of course). I can purchase 6061-T6 shaft with a ceramic coating on it, for about 20% more than steel shaft. That is something that I certainly could drill and tap.
Anyone use it? It's manufactured by a company called Simplicity, and is called feather-shaft.
http://www.pacific-bearing.com/files/pdf/shafting.pdf
Zeph