So here is the second prototype's work in progress pictures.
Yes, it would have been quicker to start with a square bar, but I am using the stock I bought to make DE handles as a starting point:
Once I had a block roughly of the size I wanted, I cut it in 1/2, so that I can make two heads:
Trim the length for each block:
Mill the cavity for the blade. Last time I only had about 0.001" clearance on each side, but this time I have about 0.002" on each side:
I then drilled the 4x holes for the magnets - now they sit much closer to the blade:
I then worked on the angle with the handle. I made the angle a few degrees smaller than before:
Then started to trim/bevel a little while I had the end mill in place:
Then drill and tap (M5x0.8):
Since I wanted a nicer appearance, I am tapping a blind hole, so I finished by hand:
I then marked the screw depth and cut it on my bandsaw:
Then seal in place:
Here is how it looks with the new larger magnets, and the small gold-plated thin disks on top:
It is hard to see due to the reflections, but the wall thickness between the magnets and the top surface is very small, probably 0.005"-0.010":
I then sanded smooth the edges/corners to blend everything what will be touching the face:
Of course this head is MUCH larger and heavier than the first one (I wanted to see how it shaved before trimming it), but this is how the two prototypes look like:
So I shaved with it once, to see how it felt. I liked the smaller angle better, and it worked great, so I can then started the trimming work. This was more free hand - I used visual clues as to how much to take on each side, and tried to keep both sides "similar". I basically removed the "fat" on this prototype razor head:
And I ended up with this, which feels much better, and is just a tiny bit heavier than the first prototype:
And with one of my first Ti prototype DE handles:
And with the Feather Guard I shaved with yesterday and this morning:
and two "scary" shots of the fully exposed edge:
Will