My issue was with no viewers or commenters had the very basic understanding of tool support or afraid to mention it. If I wanted to go all in I could have mentioned. Aluminium is softer than copper. Or protecting a parts finish is achieved by spreading the clamping load, not condensing it onto a thin line. Or that the clamping tabs were not required to protect the hardened jaws from the soft set screws.....
I think that 99.9999% of the commenters are from people with no practical machining knowledge whatsoever.
This view comes from watching a ****tonne of Paki truck and 3rd world manufacturing where the commenters gush over every wildly inefficient and completely unsafe repairs.
As to the video at hand.
8:35 is a good example of his intelligence overpowering his shop knowledge. He maths out all of the time saving steps he's going to use, and every aspect of this is going to cost him buckets of time and put a lot of wear on his "Finish" tooling.
Not to mention the horrendous sickout on the 1/4" endmill.
Just lay out your boundaries with dychem, then get in there with a 1/2" mill and blast all of the material out saving .050 all around for cleanup with the 1/4" mill. This can even be done with dull tooling as your not after finish at this point.
In his defense he did say he overthought the whole thing, but those lil tabs, while completely un necessary were kinds a nice touch.
Not at all needed for this, but a neat idea to stash away for some other application.
If we look at where he got the new endmills, this was a disaster waiting to happen.
He needed an extra 1/4"of flute length and the undercut endmill was the right idea, but the ones he was giver were clearenced for 2" and werent the right tool for the job. They were beautiful endmills, but more suited for taking .010 material way deep down in a pocket an the rare occasion that solution is needed, not for this.
If you look at 10:40 its no wonder he breaks this one, he's staring into the work when the info he should be relying on is on the DRO.