So I'm about to try another test to see if I can cut my beveled edge all the way through my 2" thick piece of foam
so I can get my 45 degree edge all the way to the bottom.
To enable my 3/8 ball nose bit to cut through my 2" foam, I set up my job size as being 2.25 thick. I'm thinking this
will enable my ball nose to cut through into the spoilboard about .2", which should give me a clean cut through.
However, when I ran the preview I noticed that the 1/2" end mill I'm using for clearance doesn't cut beyond the
perimeter, and the 3/8 ball nose bit is actually making the last cuts in the full depth of the material. That will be
a problem because my ball nose bit only has a cutting edge of 1.5"
I did a quick search and found that ball nose bits with a cutting edge length of 2.5" are 3/4" diameter, and run about $300...
So now I'm wondering if there's a way to make my 1/2" end mill do the clearance cut a little wider so my 3/8
ball nose can finish the profile with just the tip... Any suggestions?