Well, I know it can be done this way;

General CNC CNC Routers
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1

Well, I know it can be done this way; but there’s got to be an easier way.

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2

I didn’t chime in on your other post since I’m pretty new to this, but what’s the reason you couldn’t do this with a smaller end mill and do it as a pocket instead of doing it all at once with a large counterbore?

3

That might have worked, and would’ve likely been my next option; but you have to have either a mill or another CNC that is capable of properly cutting aluminum. I don’t have those, but a friend has something that might have worked. However, another issue was that the beam is about 1200 mm (over 3 ft long) and heavy. It wouldn’t have easily fit on any other machine.

4

Easiest without a mill would be a drill jig similar (but larger)
https://8020.net/catalog/category/view/s/shop/id/837/?cat=2156

5

@Mark_Fuller I must have missed that. But I’m finally getting there, I think

6

I didn’t see a jig for the counterbore

7

You’d have to modify theirs or build your own jig. Same basic idea though.