How much deflection to expect...

[Wal]

Heh, yeah - I guess it is a bit bag-pipey - should've had it sprayed tartan..!

I didn't use coolant on the profile cuts into the sheet, Jonathan. I may give it a go sometime, but to be honest the tearing was brutal from the moment the mill touched the surface, whereas the 6082 billet cut very nicely! I'm trying to get hold of some 6082 sheet (ali warehouse don't carry it) so if there's anywhere you can recommend then do let me know!

Cheers!

Wal.

[Jonathan]

Bear in mind coolant doesn't just cool - it lowers the coefficient of friction (i.e. it lubricates) between the tool and the metal. That means less heat is generated to start with...