On the second read, I agree with HFD. This would be a good way to handle it. It would still be a bit tricky and require some good setup. I would mill the bottom first, however I would mill out the hole completely in the first op. Then you could use this to setup the second cut precisely in the center.
A cheap center finder would really help you out here. It sound like because your vise jaws changed position after the initial cut, you were not able to get exact center on the second.
That said, if this clip isn't really load bearing, this part looks like a good candidate for injection molding in plastic. Small oddball shapes like this are not all that costly in quantities of 500 and more. You have to make it worth the mold cost initially, so the more you need, the cheaper they become. Some plastics are incredibly strong especially for small parts.
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Lee |