Hi Gene
You seem to be making a real meal out of a DB9 slot

Why not just make the cutout this shape;
https://www.aliexpress.com/item/10PCS-Full-Height-serial-port-Bracket-for-DB9-DB15-DB25-interface-Computer-Case-PCI-slot-baffle/32880851198.html

easier to assemble
can invert plug later if you wish
easier to machine


On Mon, 17 Dec 2018 at 00:28, Gene Heskett <ghesk...@shentel.net> wrote:

> Greetings all;
>
> I found I have a 4mm mill, which will give a closer match to the rounded
> corner radius of the db pattern.
>
> In laying  out the cuts to do a db25 length pattern, I am mirroring 1/2
> of the max overall length of of the wider top, which is 1.537" including
> the tool diameter of 0.157480314961 that needs to be subtracted from
> that overall length. So thats [[1.537-0.157480314961]/2] to get a
> measurement left and right and of the geometric the center of the
> pattern.  That move is to be done by adding 1/2 the dsubs
> height(0.334"/2=.167)-tool_rad(0.0787401574803) to its current
> centerline height for that 1st move. That move will also include the Z
> decrement since this panel is plenty thick enough to deflect the tool,
> so I am climb cutting (ccw around the inside of the desired pattern,
> while digging progressive deeper.
>
> Then the mechanical pattern from there to the lower left end/side isn't
> speced in run length, this shorter run isn't specified except as a 10
> degree angle. With the tool stopping at the mirror of the prior y
> height.
>
> How do I calculate that x offset from the x=0 centerline for the -target
> of that end move? which then turns in the + x target for the next move,
> and the a move back to the starting point which will then be done at the
> mirror of the first 10 degree angle.
>
> What I want to do is pass 4 vars to the CALL driving the machine to the
> center of any hole (11 needed), finish the move to the edge of the hole
> by adding all the little offsets used to those 4 values passed as
> arguments to the sub that does the work. I broke a 3rd .125 mill and
> bent a fixture bolt last night trying to carve it again because I'd
> missed a g54 insurance call on a restart. Thats fixed now, but this is
> getting old and ex$pensive.
>
> And I've decided to make 2 of these so I can put the 2nd one on this
> mill, along with another 15 volts of stepper motor voltage.  That of
> course will then lead to the stripping the gear box off it and mounting
> the 400 watt spindle motor from the 7x12 (TLM's former spindle motor),
> and about a 3x1 spindle speedup, an encoder and a better mister. If the
> bigger motor kills the controller I've already souped up with a much
> heavier hexfet, shrug. I'll send Jon some more green to make me another
> of his. They work VERY nice for spindle control. :)
>
>
> Thanks all for any help with the math. And have a Merry Christmas.
>
> --
> Cheers, Gene Heskett
> --
> "There are four boxes to be used in defense of liberty:
>  soap, ballot, jury, and ammo. Please use in that order."
> -Ed Howdershelt (Author)
> Genes Web page <http://geneslinuxbox.net:6309/gene>
>
>
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