That's what I was thinking... Still trying to figure out the trick to machining Delrin,I've either gotten a very rough finish or a melted finish that looks like crap. Admittedly I haven't worked with it much but ill do some experimenting...
Also planning on making some bar ends and a GPS bracket this week hehe
I would say they you need a curved tip like a 'U' to make the side cuts.
Perpendicular and internal angles can be done with a paring tool.
You have to play with it - rate of cut and speed of rotation vs heat generated.
Yes tools heat up and the heat will affect your cut... try lubricating with cutting fluid or spray water to keep the tip cool would be my best suggestion. Delrin is resistant to oil and cutting coolant - water will only affect your tools if you do not clean it up after cutting.
Your finish depends on the tools you use - make sure they are very sharp... as I don't think you will get a nice finish with any sanding or file work like with metal - it would just roughen the surface as it heats and melts.
Could weld some up and make them hollow for weight out of pipe and make a cool design!
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