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The Sequel - Oh Blimey I bought a CNC Lathe (Beaver TC 20)
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awemawson:
And here is an illustration of the Groove approach and it's associated oops ! The two hole patterns are here rotated 15 degrees relative to each other to give maximum clearance. Trying other rotations results in problems elsewhere.

. . . .my head hurts 1
WeldingRod:
I hate to suggest 1mm cord...

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awemawson:
Yes I agree, but A:/ I'm not sure how well it will pressure seal, and B:/ I don't fancy cutting those oval grooves with a 1 mm ball ended mill in EN24T, but then I'm just a coward  :clap:

Experimentation called for I think
WeldingRod:
They seal just fine.  We use them at 10,000 psi and up.  Kind of easy to nip/ damage/screw up... You should buy the harder durometer, though.  As a face seal you wont have any issues and it will give you more margin on extrusion.  You don't get a lot of squeeze on them.

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WeldingRod:
Oh, I forgot: square groove corners are fine.  It's not worth messing with a ball end mill.

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