what about using a very hot needle the right size to melt/push holes in the polycarb?
Ive forgot what the top of the cascade looks like, but have you considered making the jets a seperate part, like the accelerator plate like with the dd rbx, as this would make it easyer as you wouldntneed to EDM it - not sure what this means but I assume the way the rest of the top is machined.. This might make it difficult to align the jets with the cups?
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