I had spent an hour or two hacking together a plan to cut these castings with some soft jaws and other fixtures. I wasn’t really feeling great about it.
I decided to put all the toolpaths on the part as if I could reach all the features and spent a few minutes day-dreaming about the perfect fixture. I took more time to design and make the fixture but it was much more confidence-inspiring.
Perpendicular holes with counterbores on all sides is a unique challenge. This fixture allowed us to have total dimensional control and ended up being really rewarding when complete.