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Ok, so today I went and tried out the thread mill. I got a 2D full length cutter and ran the machine with 2 pecks at half the pitch (0.75mm). It worked really well at 60m/min and 0.05mm feed and came out just slightly undersize. Rather than mess about adjusting the offset I simply ran a tap down...

Well, I should start by thanking everyone for their constructive replies. I think I will try and spend some more time here in the future - perhaps I might even be able to offer some help (probably design rather than machining!). Rather than reply to each post individually I will respond in...

Mhajicek, I am thinking that might be the sensible solution as it gives me flexibility with odd sized threads. I just never considered it as I have never had a cnc machine before and still think very much conventional manual machines. I also got told that the Hurco is not great with rigid...

Digger Doug, Not certain I get what you meant but the part is a bed plate for a wire drive - think in terms of a die set and you have something similar I suppose. Typically this is the material used - it is only there to hold everything in the correct place, no wear or moving parts in contact...

GMC1724, Yes, I started out with 350rpm on the M6 but dropped it by 50% and reduced the depth after the first tap broke. Thinking I would be smart, I dropped the speed to 164 in the hope of a straightforward end to the job..... not that that has worked to plan. Mark

Gregormarwick, I intend to have a closer look at the hardness in the morning - it certainly wasn't "hard" but it was not soft either. I didn't try too hard at the time in case I slipped and hit the bed (on my brand new machine). Mark

Thanks Gregormarwick, I anticipated it would be soft and I only took it as it was all the profiler had in stock (everything else was going to need to come out of a slab (That I bought). Perhaps I should have got a cold rolled flat and had it water jet to shape - nothing like 20-20 hindsight. As...

Thanks for the reply Boosted. I can mill threads on the VM but had avoided it as I thought a few holes would be easy to thread with a tap - I think it might be time to revisit that decision.... The prospect of removing the remnants has me full of joy :(

This is my first post here so I should point out that I am in the UK and that I am a design engineer (production automation machines) who got fed up being let down by local subcontract shops and have bought a new mill and lathe (Hurco VM20i and TM10). I have spent several years making prototype...