Quote:
Originally posted by #Rotor
JD, how is this for an idea. pre drill the holes such that when you go with the final sqr-end bit, that it's diameter is such that each hole just barely cuts into one another.
the only reason this is not possible with a drill-press and normal drill-bits, is the fact that the bits are so bendy and braky.. 
this will give the formed pins the perfect shape. the Sqr-end bit will also not be so prone to wander, as it will be cutting on the perpendicular plane to the downward force applied.
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You could do it with a ball nosed endmill and plung drilling with it and then make the final run with a sqare ended endmill to make the bottoms flat. Drill bits, as I found out this weekend, are to flexable. Even with the mill they didn't make a perfect grid. One of the projects on my list is to use ball nosed endmills for the grid holes. Might make the pins to small though as pointed out. I will have to draw it out a few times and visualize.
