Whiz- That's my typical method for touching off. I like to set my zero with a feeler and let it rapid to the height *(safe Z) before it comes down. That finish cut pass to me on .125 end-mill is way to high. Despite the fact that your using HSM toolpaths, I can only imagine what your tool deflection is. I'm a new advocate of something I wanted to try for a very long time. When my trial is done, I am purchasing it... download GWizard from CNCcookbook. I have been using it to estimate my feeds and speeds and you really cannot go wrong with it, I'm usually a little more conservative so i'll bump down the recommended. I'm sure if you input that data in Gwizard; it would have spit out a high deflection which is instant killer on a small end-mill.


I use my oiler too, but get yourself a nice hand-pump action oiler. I have one with a braided adjustable end and use it to get into any areas the one-shot does not. I used it on my old mill and I use it now on the Torus Pro; it's a simple upgrade.

BTW- What printer did you use for your part?

Hope this helps somewhat.

-Jason