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Hi Tug, yes quenched in water and then tempered. It was a bit brittle but I was also getting too keen! Will remember about oil hardening next time thanks. Cheers, Mark

Sorry for such a late reply, I have been solid with work since posting this and not had a chance to do any more modelling. Thanks Ramon, thats the sort of cutter I made except I did it with one 'tooth' and threaded the centre of the cutter. This worked very well for one side of the cylinder and...

Thanks Charles, that was the route I was thinking of taking. Just wondering if there is a machining way of cutting the teeth as filing that small could be hit or miss.

I am currently building a McOnie Oscillating Engine and have a requirement to spot face the backs of the cylinder faces where the end caps bolt through. This needs a spot facing tool that can be pulled through the 8BA clearance hole and run in a drill (or some method). Most of my machining is...