Brief Description: Flap switch thingy machining the RIGHT way
This entry written on 8/28/2016; no estimate for hours, in the shop or in the ER...
I got a scrap Al cover plate from work that I could make a flap-shaped thing to go on the flap toggle switch. I cut a rough cube, roughly 1", from it with a bandsaw. There were two adjoining machined sides. Plan: put one machined-side on the drill press table to drill blind hole for switch's lever in the middle of the cube, then rotatecube 90 deg putting the adjoining machined-side down and cross-drill thru the blind hole near the edge of the cube. The cross-drilled thru holes would be tapped for 4-40 set screws to fix the flap-thingy to the switch. But first I could secure a rod in the blind hole, providing a handle for rough sawing an airfoil shape out of the cube, and finishing it up nicely on the belt sander.
The plan worked out great, especially once the cube was SAFELY drilled, as pictured below. In the interests of public safety and my dignity, I shant describe unsafe methods of drill that I neither deny nor confirm are known to me.
The other two images result from playing around with the student version of SolidWorks EAA membership now entitles one to download.