Alternative to tabs for work holding? Double-sided tap? 0.5mm thick, long tabs?

[mattnedgus]

Also don't be afraid to cut deep. One of the bigger mistakes in Ali or other materials is cutting too shallow and overheating the cutter. You want nice big chips that take the heat with them. If your making dust your doing it wrong.!!

Thanks Jazz - it's interesting to get an idea of what others use. One of the problem-areas I've had is in my DOC's, feeds and speeds cutting baltic birch - I cut as deep as the cutter is wide (typically 6 and 8mm) with speeds of 13500RPM and feeds of 5000mm/min at the moment. I've been trying to get those chips nice and big while reducing some chatter and some instances where the cutter bites too deep and creates something similar to chatter but slightly deeper and further apart. It's frustrating trying to 'dial in' settings that work reliably to produce parts that need less finishing by hand! I'm considering rebuilding the Z axis to try and help eliminate some of the flex that must be present in the machine.