Tonight I worked on the lightening cutouts on the F-633 control column mounts. I first laid out the cutouts on each part per plan. (I used blue sharpie as poor man's Prussian blue, then scribed the cut lines). I then measured back 1/4" from each line and placed the center of the corner radius holes at the intersections. I drilled each corner by stepping up through about four sizes until I got to a 1/2" bit, then made the cutout using my bandsaw.
I tried using a 3/16" burr in my drill press at high RPM to smooth the sawcut edges, but the bit was too short for the chuck to clear the upright on the angle. I also didn't have a good way to set up a fence to make the line nice and straight. My vixen file and the scotchbrite wheel worked fine, but was quite tedious. Overall, this is a heck of a lot of work to save what I caclulate to be a bit over an ounce per mount...