Half way done

One section done, one section half machined.  Now that I have working toolpaths, I can mostly copy/pasted between parts/sides and just re-select the appropriate geometry.  

The first finished section of the part:

Here's a quick look at all the toolpaths.  Once it's done I'll do a real blog post with machining details:

 

The scrap pile grows....

The most recent attempt was so close.  As usual, got wrecked by the final tool change.  Not sure what happened (maybe I just forgot to touch off?), but the final tool, which finished the linear guide grooves, was about 1mm too deep.  

This op is 1/6 of the whole part.  Eventually 3 of these, machined on both sides, will get joined by a tie rod.

3mm drill shank in the 3mm slot.  The walls are actually parallel now.

Face spline for locating the 3 pieces and transmitting torque: