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I haven’t used this particular variant, and I believe they’re specials so I don’t know price or availability, but I wonder if this might be another option to consider. I *have* had Balax make some custom 1/4-80 form taps for Ti, and was happy with the results.

Regarding roll tapping, and your concerns about the crest of the internal thread in coarse pitches:

It looks like SMW Autoblok is still around, but am not sure that's the same entity or not....

Here’s another vote for something like that Dell....I’ve got a 7740 that’s a couple of years old, and have had a couple of other “Precision” laptops that have all served well.

That shaft looks nice! I love it that you’ve got a fly helping you program it in SolidCam in your next to last pic! Your secret is out....

Rego-Fix stuff is great....and yes, I’m the chump that writes the checks! I’ve got a bunch of ER-16 & 32 collet chucks and I don’t even bother to check them anymore. Maybe I ought to and report back, but they’re essentially dead nuts in my experience. All bets are off with cheapo collets, and...

We’ve got Volumill in TopSolid 7 and use it quite a bit. We’ve also got trochoidal but don’t use that nearly as often because VM is a better fit. Yes, I can see an older/slower control being unable to really take full advantage of a VM toolpath, and in that case a trochoidal path might work...

Gotta love it-HerdingCats threadmill may cause cancer! Go Prop 65!

A friend has some reducing bushings that he uses in a small boring head, but am not sure where he got them (they don’t look home made, hardened + ground). They’re properly made like yours, split like you’d expect from a collet.

You're welcome-let us all know how it goes! Did that STEP file work better for you?

I forgot to mention that the IGES file originated from SWX2008 (according to the file header), so it has now made the "round trip." IGES is kinda a relic these days with stuff like STEP or Parasolid often giving better results for solid and surface data.

Hi Paul: I've just emailed you the translated files-let me know if this does the trick, OK? The files were quite large, so I have sent them as separate emails (they haven't bounced-yet). You will have a native SWX2021 file, as well as a few different Parasolid files that should read into SWX...

Hi Herding Cats: I'd be happy to have a crack at this if you haven't got it sorted already. I figure between SWX and TopSolid there's got to be a way to do this. Cheers, Brian

Wow-that’s good to hear! You found someone nearby to do the grinding, or your material supplier just did it and surprised you?

Oh man! I guess I had forgotten most of the details besides the broken legs-yikes! Glad you're still with us, thought it sounds like you used up about 8 of your 9 lives with that one!

I've used a couple of the helical flute ones, and they're definitely nicer-sounding than the straight flute ones, but I don't have enough mileage on them yet to know if they last longer....seems like they would, though.

Wow! I’m glad g-coder05 weighed in on this one! I kinda recall he had lots of experience with big parts & machines. (It must have been that story about getting a broken leg running some big VTL!). I’ve never dealt with stuff that big (a big part here is ~20” x 40” or so-LOL), but for the...

I realize this doesn’t really answer your question, but I wonder if you have considered getting this material Blanchard ground and just skipping this step yourself? (Is there much additional work in the part, or is this the bulk of the job?). I haven’t had to deal with plates this large...

Any time I've got much stock to remove from cold-finished material, I'll try to get it into the heat treater first for a stress-relief/anneal operation. I have found that I'm usually time and money ahead by doing so. And to answer your question about adding vs. removing stresses from your...