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Dept store Quartermaster
Join Date: Jul 2001
Location: I'm right here Tati
Posts: 19,867
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Something like the sway bar mount could be done will in a mill with one tool change. Once the basic dimensions of the hole are achieved, just process the corners with a small diameter end mill. The slight radius in the corner is not an issue as the clamping force is on the flats, not the corners. 5Axis also mentioned the broaching machines, and yes they work well. These were WW1 technology and can probably be had for scrap prices.
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Cornpoppin' Pony Soldier
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