Ho do you measure end mill diameters?

[antsals]

You can buy a micrometer just for this job. I'm sure if you hunt around eBay you should be able to pick some up. The have two faces opposite the anvil. I'll see if I can get a picture of a set.

Ant

[blackburn mark]

cut on some scrap and measure what it actually cuts.

i guess we all do a bit of that in a sense when we are polishing a g-code file

you have the added complication of climb vs conventional and slot cutting flexing tools this way and that.
i do quite a bit with 3.175mm (1/8) tooling (lots of flex) hence the g-code polishing..... on my first run of a complex part i assume it will have small errors that may make assembly a bit of a pain... tune the code run again etc.... usualy my third part is a winner and that g-code file goes into a file reserved for good code

[HankMcSpank]

Thanks guys....I'll go with the cut/measure option!