Richard Chiarello sent a repair project. He sent a part of a device for rewinding film. The plastic part was broken. It is essentially a cylinder flattened on one end and slotted on the other. A small handle is affixed to this part.
Began the piece with a 1.5" long by 0.5" square aluminum bar. Chucked this in the four-jaw chuck and turned one end down to 0.348" and faced it. Placed this end in the three-jaw chuck protected with cardboard.
Take care not to place the cardboard overlap against a chuck jaw!
Finished this end to the same diameter and faced it. Turned 1.260" down to 0.275". The wide end was faced down from 0.33" to 0.180" long. Center drilled the opposite end and drilled with a #43 drill bit and tapped the hole with a 4-40 tap.
Set the part up on the mill table in an angle block. After locating the top and end of the work piece used the 3/8" end mill to cut the flat to a depth of 0.275" - 0.218" = 0.050" and in from the end 0.250". The other end was then set up for cutting the slot. This was cut 1/8" deep with a 1/8" end mill. A screw was cut to length and a washer was found to match.
The part was returned to Dick, a happy customer.