Today's update:
I started on shaping the crossheads. I used a plunge-cutting-rounding-over mini-router bit from my dremel-clone to shape it.
![](http://velvet-art.smugmug.com/photos/613249840_ZfKRS-L.jpg)
Then after centering it I cut it down both sides and the middle.
![](http://velvet-art.smugmug.com/photos/613250357_qnoh6-L.jpg)
Then the other one, and then I marked them both up for milling.
![](http://velvet-art.smugmug.com/photos/613250171_WANm9-M.jpg)
Mounted in the vice on some parallels and cut down both sides of the fork.
![](http://velvet-art.smugmug.com/photos/613249955_GWRUQ-L.jpg)
![](http://velvet-art.smugmug.com/photos/613250427_oZFsW-M.jpg)
Then I milled out the centre of the fork, opened out one hole from 3mm to 4mm, and then rounded off some edges and then spent a fair bit of time in smoothing out with 360, 600, and then 1000 grit wet-n-dry, and then re-reamed the deep 4mm holes for the crosshead rods and tapped the M3 hole.
![](http://velvet-art.smugmug.com/photos/613250233_fogGz-L.jpg)
![](http://velvet-art.smugmug.com/photos/613250302_Um6Ao-L.jpg)
And here it is next to the unmilled crosshead block.
![](http://velvet-art.smugmug.com/photos/613250051_4nszB-M.jpg)
![](http://velvet-art.smugmug.com/photos/613249919_CPdZ4-M.jpg)
As you can see on the unmilled crosshead, I've drilled 2 6mm holes in order to get a nice curve profile between the upright guide portion and the fork part.
I had been toying with the idea of milling a couple of, say 2mm slots to expose part of the crosshead-rods, but I didnt have a 2mm or smaller cutter and I wasnt sure if it would negatively effect the crossheads themselves.
That's all that I was able to get done today, the shaping took a little longer than I thought, but I didnt want to rush at it as it would be a real bummer to mess up on one of these crossheads. I'll work on the 2nd crosshead over the weekend.
Tim