[How-To] Cutting a 90° slot/groove in a 1.5" bar.

Just for fun said:
Well, I got it done. I used my 1/2" chamfer tool. It didn't work real well but it worked. I didn't go a 1/4" deep as planned. I just thought it didn't look right, I stopped at an 1/8" deep for the deep cut. I did cut a shallower groove as @Parlo suggested. As mentioned the tip does not like to cut, shallow cuts were the answer.

I thought the groove turned OK for being in mystery metal and using a tool not designed for cutting V grooves. Now on to the rest of the project.

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They turned out very well. These cutters are called chamfer cutters as they are primarily designed to cut chamfers and not vee grooves. They need to be run very fast as the surface speed at the tip is zero, engraving machines have really high spindle speeds for this. Great for chamfers but not for vees, if you can ever tilt the part and use a standard end mill you will get much better results as the sharp corner is actually cutting and the tools are far cheaper.
 
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