So this is what I’ve been able to accomplish so far:
Flattened base and two sides using a large shell mill:
Drill the mounting holes and define layout for the fence support bar bores:
Drill the first holes using a 1/2″ x 8″ bit:
Open the holes to a larger size with stepped drills:
Open the top hole with a roughing mill to allow the use of a larger end-mill tool holder:
Bore the bottom hole using a 1-1/2″ rough end mill:
Use the adjustable boring bar to open the hole to finished dimensions:
Repeat the same steps for the other side:
Use the adjustable boring bar to finish both sides to the final dimensions:
Ok, so what you can’t see here is that the table is locked in the Y axis. This ensures proper alignment (height) of the fence bars.
The next step is to clean up the surface finishes and then start with the lathe work on the fence bars.
Here’s a link to a video version of the description.
Good work, great blog, keep going.