Milling a slot, with light equipment

I'd do it exactly as you describe doing it last time. Tool wear mainly occurs when you push the tool hard so you aren't going to hurt your milling cutters if you take it steady. Drilling and sawing and then still having to mill anyway strikes me as having a dog and still barking yourself.

Thanks Dave I think I have a bit of a mean streak (& not a lot of money) so I tend to err on the side of - milling cutters are (relatively) expensive, whereas drills, sawblades & my muscles come cheap(ish). But you are right, I think I'll just mill it many thanks Mike

In article , MikeH_QB writes

I agree with Dave, sod the chain drilling. I suspect you are more likely to damage your cutter by trying to plough through a series of drilled holes, as it may (depending on how much you can saw out) be experiencing "breakthrough" conditions at each hole.

BTW, if you wish to cut a slot in one go, do be sure to use a slot drill rather than an end mill; they are designed for this. An end mill (unless very much bigger than 6mm) will almost always give a wobble at the end of the slot, as the forward tooth leaves the work. Your way (5.5mm then

David