Parts are done now. The shaping worked great.
I could have saved about 45 minutes using a square end mill. A lot of attention and extra programming time required with this method to blend the 30 degree side walls with the floor of the cut and the parts maybe not quite so nice. Cutters of course cheap.
Could have saved about 1.25 hours using a 60 degree included angle end mill with .130 minor diameter. Cutters were $130 each minimum 3 pcs so $390 total.
Used a topnotch ntp3r insert ground to .130 tip flat at a cost of $130 for holder and insert and about a half hour to grind.
So shaping was the way to go for 150 pcs with last time I ran the parts over 5 years ago. The topnotch insert will hang in there for maybe 1000 pcs I think.
Maybe someday will run big enough qty to justify a custom milling cutter.
Thanks for all the ideas!
How about a pix or 2 of the finished part ?