[dfearnow]

I really want to quote this job that came to me. Its 1-3/4 x 1-3/4 x .120 wall x 12.00 long steel tubing. They are wanting half of the square milled out ( so it looks like an L) 4" down 1 side. I have done thin wall tubing jobs in the past, and they have always been a head ache when it comes to milling out the integrity. if i try and just straight profile it, using the full dia of the end mill, the material likes to curl up and not drop off. If I try the gentle approach and lightly highspeed machine it out,once I take of 1 side, the other side is flimsy, and likes to vibrate all over the place.
Is there a method im missing? I was maybe thinking about making ID spacers to keep the vibration down. But I'm sure the tubing is not going to be consistent enough to make just 1 spacer. I have over 200 parts to machine.

[chuckorlando]

Have your helper cut the center out with an angle grinder. Then just clean it up on the mill. I know I can rip thin wall like that fast as all get out with some cut off's

[chuckorlando]

Or maybe leave .01 on both sides and hit it out with a hammer.