Machining a double D

[Dean jeffery]

EDM would be expensive if you were paying someone else to do it, however if you've got time and are willing to build a machine, then it wouldn't be quite so bad, but it depends on what your goals are.
Another option could be to machine the shape as near as possible on a mill, then use a small shaper and custom cutter to cut the sharp corners.
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Dealing with Ti isn't that much different from stainless. You've got to use sharp tools and ensure they never rub as it'll workharden in the blink of an eye. It also produces swarf with a far shaper edge than stainless, so you have to be careful handling it.

Cheers for the info but EDM is out of my league, think I will drill the corners and see how it looks. This is the easiest option I think, failing that machine to has close has pos like you say and then shunt be to hard to make a broach just to take the corners out, should be able to use a small press then.
Failing both these options I would have see about getting them done else where, just wanted to make these with paying anybody to do any machine work.

Cheers