C96 Cutaways

[sheepherder]

Originally Posted by Olle

I figure an affordable job would have to include sweet talking, after hours, off the books and a case of beer.

Yes, any EDM is slow and also messy (the electrolyte solution). There was a famous thread on the Roderus Forum of a member making an AR-15 receiver out of a solid block of aluminum. He used a CNC Workstation, a 1/4" ball end mill [IIRC}, at 10,000rpm removing .006" at a time and the machine ran all night doing one half at a time. If it was done during work hours and at shop rates it would not be cost-effective. Wire-EDM is similar in practice/cost. My mag tunnel was a simple cut and I supplied the work drilled for the wire to be inserted and all dimensions, tolerances, and clearances. The shop ran it after closing and when they came back in the morning it was done. I did two, btw. And it was expensive. I'll drill & broach next time.

Another thing to consider is that the EDM leaves a somewhat rough and discolored surface, almost like a fine sandblasted or etched finish.

Yes, a satin finish. Acceptable for interior surfaces, not so much for outers.