Was asked to build a large letter for an upcoming wedding - roughly 2' x 3', and 4" thick. (apparently that's an 'in thing' for weddings now - guests sign this big letter).
Used a 1/2" end mill to carve out the letter. I hadn't cut anything that deep before, and my chip removal would not remove the chips from the 1/2" 'channel' as it cut deeper. I ended up having to pause the cut, use a screwdriver to pry up the chips, vacuum them up with a shop vac, then keep going.
This took approximately forever (turning a ~25 min cut into several hours of cleaning and vacuuming).
What do others do for these deep cuts for chip removal? There must be a better way.
Things I considered after the fact:
1) Air compressor to blow out the chips - will make a big mess but would probably work pretty quickly
2) Cutting the project 2 sided, so it's not so deep. Not crazy about the extra work to flip it, but might work.