Update time!
Ok sooo I worked on the handle tonight.. Only had a couple hours to play.
I tapped the top of the handle in 1/2-20... why? just because.. no real reason on that thread, other than it was a finer thread than the others in the generic tap set I had.
So here we go..
Turned the .625 hex bar down some so I could tap it.
But as its a bit larger diameter.. and the tap was taking some.. torque on it.. the cheap cast holder... well..... you can see the result.
Guess I need to get my ass in gear on the Die Holder project.... BUt I will need the peck drill for the die holder.. LOL.

Judicious use of a 1" wrench.. and all was better.

Not so bad... I think.

Rounding the hex bar.

Ball turner with the cutter reversed.. and kicked way out.. I didnt measure it.. but its way out there. I am thinking its a good 2.25 inches from center, if not 2.5 inches.
The end result is a very smooth curved cut that is very gentle.
BTW.. the cutter holder I made.. REALLY came in handy with the extended legs on it.. as I was able to move it way out and still have all 4 screws lock it in place securely.
I have video of it in use.. but need to compile a clip from the activities. (its late just posting for now)

End result of the 4 Cuts...

Complete handle cuts.. minus the ball (need to buy some brass) and minus the cuts for the slot

A interesting problem.. I had to tackle.. and didnt know how to.. so I guessed.. and it didnt work as good as I would like.. so I will need to learn a better method for this.
The round bar.. has a slot cut.
I had to cut it deeper.. and needed to re-mount it in the vice.
SO I put it on the parallels.. got it to the right height.
Then I put a round bar in the mill.. and lowered it into the slot.. and then ran the cross slide till the part was touching the rod. Then rotated it till it was flush.. and snugged the vice.. then re-checked.. and locked it down.
As it turns out it was off in the bottom by 1/16 or so of an inch. AKA the bar stock was rotated slightly.
Suggestions on how to do that would be greatly appreciated.... it exceeds my machining experience.



Tomorrow after getting the brass for the knob, a block of metal to make tool holders for the QCTP, and a bar to queue up for some die holders. and the new tool.. and hopefully a dovetail mill...

I will try to get in there and get more done.
See generic American COC to follow...