MILLING THE SLOTS IN THE CYLINDER HEAD. I MADE A HOLDING FIXTURE, BOLTING THE HEAD TO IT TO SECURE IT FOR MILLING. THE 4 BOLT HOLES IN THE HEAD WERE COUNTERSUNK TO JUST BELOW WHERE THE BOTTOM OF THE SLOTS WOULD BE.
The cylinder head is bolted to the plate, using the same socket head cap screws used to secure it to the cylinder. A line has been scribed down the center for the first groove. Three additional grooves will be milled on each side of the center one.
The holding fixture is simply an Aluminum block, with 4 tapped holes for the head.
I used the Vernon Horizontal mill to cut the slots. It could certainly be done on a vertical mill as well. I chose the Vernon because I like it for these types of cuts, and its faster. Also, I had a cutter that is .109 wide, with a rounded end. This cutter makes very nice looking slots, like a ball-nose end mill. The slots are 0.150 deep, with 0.100 distance between. The bolts had been countersunk enough so the top would be just below the slot depth.
All polished and ready to mount to the cylinder. Some delicate filing, and then buffing on a fiber wheel removed all the burrs and restored a nice finish.
The head is slotted, still on the fixture. Now to get rid of all those pesky burrs!
PAGE LINKS FOR CONSTRUCTING THE EAGLE
