Cutting dovetail for sight!

I am not familiar with the mill you mention but the key to cutting dovetails is rigidity. A flimsy mill table, flimsy vise or slop in the ways can lead to problems and broken dovetail cutters. The cutters are very fragile and the smallest unwanted movement in your setup can cause breakage. A dovetail has to be cut full depth in one pass so the load is high on the cutting tool nessitating slow and easy feed rates.

Mill dovetails in two cuts. The first cut is done with a standard endmill and takes out most of the material. The second cut just takes out the profile of the dovetail cutter. Rigidity. Lube. Proper speeds and feeds. Your machine should work fine.

Anyone ever try it by hand with files?
Successfully, that is.

If you do go that route:
Have it mounted on a solid, level base.

Get some like steel round stock, Pre-hardened 4140 or A-2, and practice on that first. That way you'll know whether you and the machine are up to the task.

But, that is what I'd do.

The best way to do it with hand files Is with a hardened steel jig that will help guide your file. Pretty foolproof that way.

Slot it first, then clean it up with the dovetail cutter.

It is often NOT for the faint of heart.
Often the location is at least surface hardened.

Starting the slot with a hacksaw may be advantageous.

All methods mentioned will work just depends on your skill level. The X2 will work just take your time and rough it in with a straight mill as mentioned. never try to take it in one cut with a dovetail mill or you will end up with an oversized dovetail.

I occasionally cut one in a blackpowder barrel with a file. Brownell's sells some nice files just for that purpose. At one time they had a guide of hardened steel but I think they have discontinued it. I cut a notch with a standard file and then do the undercuts with the specialty files.

highorder said:

Mill dovetails in two cuts. The first cut is done with a standard endmill and takes out most of the material. The second cut just takes out the profile of the dovetail cutter. Rigidity. Lube. Proper speeds and feeds. Your machine should work fine.

Click to expand...

+1 Saves grief.

Be sure you've got the correct angle dovetail cutter too. Different sights - different dimensions.

And no you don't have to cut it in one pass.

That mill should be plenty - I've cut quite a few with my Sherline mill and it has to be much less rigid.


Cat

One of the tricks (even on large milling machines) is to tihjten up the table gibs as much as possible.

You only need cross feed anyway for the most part.