I think a Jig with CNC would be faster and more accurate for large quantitys than doing it manually. Trust me I would give anything for a CNC machineThe Jig only needs to clamp the top of the atty (diameter and height specific) in the same position everytime so when you run the CNC it is all the same. What design flaws are you talking about? I believe manual drilling he will have a problem with, the tolerance is VERY tight for drilling the holes. Too far out and you'll drill into o-ring groove, too far in and you'll hit the center stem. (I ruined one in the process because of the hole drilling)
The way I finally got it perfect was to measure the distance from the stem to the o-ring groove, cut the measurment in half and spin the part in the lathe and mark a line using a 60 degree thread cutter to lightly touch the face of the part so it scribed a circular line at the measured distance. Then I had a small groove at the halfway point, so when I went to drill, I drilled on the line at the points I marked out.
It worked perfectly.
Dan
Have you ever tried to use a tool that has a swivel top? I am sorry the name has eluded me right now. It is used to find the edge of something then you measure off of that. They are accurate to +/1 .002". The tool is flat on one side and round the rest of the way. They are typically .200" in diameter.
The design flaws I am referring to is the slop built into the HAAS cnc mill. The machine he has is not meant for this fine of detail. It is only designed for +/- .005"
The tool is called an edge finder.
I will pass on your recommendation though.
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