It's getting a lot more complicated as I am rewriting it to try to minimize side cutting with the keyway cutter...    I can't turn it on it's side and do it with a tiny end mill because it's probably too deep (1/2") for a .050" or so end mill, plus I really need a fairly sharp inside corner on the underside of the "finger", plus my spindle only does 4500 rpm... 

I've been straining my brain trying to figure how to to do this without having a custom tool ground.   The answer I think is EDM, but that's not in my future any time soon. 

I think if you look at t slot millers they can do a bit of side cutting.

Just a thought, (;-) TP

Will do, thanks for the tip.   I just picked the keyway cutter flipping through a tooling catalog..    I'm an electrical engineer by trade and all I know about machining is that I want to remove all of the metal that isn't my part.

Spoken like A true chip slinger (;-)

(;-) TP