Once all the holes were roughed out I ground the sides smooth, straight, and square with a tungsten carbide burr in my die grinder. I use a short burr to get the ports close and a 6" long burr to finish them. The extra length lets me see what I'm doing and makes it easier to know that I'm square to the surface. I wear gloves for this because the carbide throws a lot of small razor sharp steel slivers. Even with the gloves I spent awhile with tweezers picking them out of my hands. Otherwise they rust in place and you get what I call carbide freckles.

Owner caption February 2010 · Photo 68 of 429