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Place an extra hole in for a tooling ball or you can make a fixture similar to a jig bore edge finder to allow the use of a phantom tooling ball.

Try a rectangular shaped pin for example .75 x 2.00 with a full .375 radius on the leading and trailing edge of the pin. You might consider 1.00 x 2.5 with a .5 radius also.

Use a rectangular horn pin with radii on the leading edge and the back edge. The radii can be a full radius, the same radius as the round horn pin you might have used. You could go with a 1.00 x...

Since the formula for deflection directly includes the thickness of the material (diameter of the horn pin) cubed, an increase in thickness is gives substantial strength. You could go with for...

I have the idea that the Elox scales are not that good. If it is you scale then what you can do is get some q tips with some alcohol and reach in between the wipers and clean the scale. That should...

Jim,
Do you have the EDM Zap pulser on your Elox or do you use those trode smashing magnets that came with the machine.
I really like the Elox because it burns so fast and the hydraulics...