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Cutting Lightsaber Gear Pummel

I'm ajusting the angle of the rotary table on the milling machine to cut the notches for the "gear" shape and the back end of the lightsaber. This mill is a Bridgeport clone with a 54x10 inch table, fairly large for my garage shop. Cutting the metal was easy, calculating the exact angles and depths for the setup took me forever to figure out. Since each tooth was cut on two different angles, the blue layout dye helped me to make sure I was cutting the correct areas.

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Uploaded on April 4, 2009
Taken on February 12, 2009