the job is an aluminium cavaty to be used as a prototype, the walls have a draft but it is so slight there is just enough room to do any work on it. the reason I need the smaller cutters is that there is detail work that has to be done in the bottom of the cavaty. the cavaty is aprox. 2.5" deep if not a little deeper and only 3"x2.5" wide/tall.
As for the cutters lasting, we have 3 or 4 small cutters that we have been using quite often and they have lasted quite a while and they have been sorely abused, as long as we don't take too deep a cut we should be ok. the other problem is that the cutters have to be ball nosed.
and the part about the grinding one to size almost made me choke on laughter. not that it isn't a good idea but the only cutters we have in stock that are more than 3.5" long are 1.5" in diameter! it would be just a little bit of grinding there!
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