The final step was to make the blind rear action screw hole a 'through' hole. Stan Ware had done this on my previous Kodiak and Pandas and it's a worthwhile modification to make. You get rid of the blind hole and the possibility of the action screw bottoming out plus you gain another 3 threads of purchase. The Kodiaks are thinner than the Pandas here so it really helps them.
Real machinists and craftsmen will have to bear with me. My apologies up front for likely violating every rule of Machine Shop 101.
I wanted to mill the hole but wasn't totally comfortable my edge finding abilities to locate off the original hole. Keeping Stan's gentle way of instructing in mind when he felt I was at a teachable moment ("C'mon, Nyhus. You
have to be smarter than a piece of
bleep-bleeping aluminum!"), I came up with this.
The hapless patient prior to the proceedure. Note the coffee cup...very important.
With my pin gauges, I measured the I.D. of the threaded hole, which was .213. I turned a piece of .0250 stock to .211 on the end to use as a locating pin in the rear hole.
Then, the locating pin went in the 1/4" collet:
The action was level in the vise with the dovetail rail spanning across the opening of the vise for support. Futzing around with the X,Y and Z got it to where the pin would just slide in the hole. Note the shop rag...Stan would kick my azz for using a greasy rag!
Lowered the mill table and swapped the 1/4" collet for the 3/8" collet and put a 3/16" O.D./3/8" shank end mill in. This is one thing I should have done differently. Had I used a piece of 3/8" stock for a locating pin, I wouldn't have needed to change collets and introduce that possibility of error.
Stepped back, took a breath, had a big drink of coffee and down in it went. Everything looked nice and centered. Tapped it with the appropriate class thread tap. You can see a small raised edge where the threads enter the cocking piece guide slot.
Touched up the edges with a narrow Arkansas stone and called it good!
Critques welcomed and encouraged!
Good shootin'. -Al