I need help

[sylvan356]

I am trying to cut a hole in the side of a piece of material that is 5/8" wide x .73" deep. The bottom of the hole must have the 5/8" radius. I have tried doing this with a 2 rail sweep and using a 1/2" ball nose bit. It cuts the hole short and does not work. I suspect that this is because it needs a negative offset to reach the edges. However, I do not know how to set this so the result is right. Is this the proper way or is there another, simpler way to do what I want? Can anyone enlighten me on the proper way to do this? I am enclosing the file. It is ultimately for a slotted headstock jig. Thanks to whoever can help!!

[litzluth]

Hi Sylvan. It looks to me like the pocket in the jig is intended to allow the jig to slip over the profile of the headstock at a known depth. If that is the case, then don't you have lots of surface area to prevent the jig from moving on the headstock? If so, couldn't you allow the 5/8" radius "holes" to intrude into the headstock area and not stop them at the headstock profile border?

[jimwill2]

If you make your 3d shapes longer (width of the piece being cut plus the radius of the bit) it should work. You'll just be cutting air it looks like.

[sylvan356]

Thanks for the suggestions. Let me explain what I am trying to do. The 5/8" holes on either side of the cut out portion are designed to allow me to glue in 5/8" bushings on either side of the jig. Because the sides of the headstock are not 90 degrees to the jig the holes must be cut at an angle. Otherwise I would have just drilled the sides out on a drill press. The headstock of this jig will ultimately have tuners in holes drilled inside the bushings. Therefore, the 5/8" cutout must be exactly centered on the sides of the neck which will sit in this jig and be 90 degrees to the side of the headstock. I hope this makes sense?