Hello, i was woundering if anyone knew a good way to cut a 10mm hexagon in the middle of 13mm peice of pvc hex. Its to make a hex coupler for rc cars. I wanted to just stand the peice of hex up on my cnc, then cut the 10mm thing inside it but the smallest bit i have is a 1/8 in. upcut. I dont think this would be small enough to use.

plunge the corners out with a drill then mill the rest , you won t have perfect corners but the part will be effective all the same

where as it pvc you can get 1/16 endmill up to 3/8 LOC drill out corner as dertsap said with a 1/32 even if you need to go deeper or up in tool size you just drill more hole offset and can clean edge with scrapper

ok, how about does anyone know about any pretty hard plastic that i would be able to melt and pour into a wooden mold maybe if that would work. Also if so, how do you go about melting plastic?

why not use fibreglass body filler , ,tough and easy to pour

do you think i could use a wood mold for that?

sure , mdf if you have some would have less change of sticking to it and will peel off easier if it does stick ,
what ever you use well oil or grease the wood so it doesnt stick ,vaseline would work well

what kind of finish does this stuff have when its done and how strong is it really

there are many types of resien do web seach and here a start http://materials.globalspec.com/Industrial-Directory/encapsulated_potting

what kind of finish does this stuff have when its done and how strong is it really

the finish all depends on how well you mold it and get the air bubbles out ,
its a fibreglass ,polymer mix ,its tough ,its not your average body filler chances are if your making a wood mold plan to do some sanding , this goes for any material you plan to pour
do a google search

how about a clear epoxy resin, how tough do you think that stuff is?