This part was made from 2.5x2.5x3" 6061 stock and required 5 jobs (HSMworks terminology for re-orienting the stock). I wanted to machine 1.125 dia. hole and perimeter to full depth from one side. Depth was ~ 2" but I didn't have a tool with flutes long enough to reach without rubbing the shank so I made one. I took a 1/2" end mill with 1.5" flute length and ground down the shank and flutes leaving only 1/2" of flute ant the bottom of the end mill. I did this by (go ahead and laugh :-), mounting a hand held grinder in the vise and ran the Tourus spindle at ~1000 rpm. Then slowly ground from the top of the shank downward. I only left 1/2" of cutting flutes due to the super long stick out from the tool holder. I took conservative cuts on the finishing passes and it all worked out well. Here's some video.
I need to look into some more tooling (boring bar etc).

https://www.youtube.com/watch?v=eeBw...ature=youtu.be