I have been using a .25’ down cut end mill that has a cutting depth of 2" to do profile toolpath cut outs but wondering if I could use a .125" end mill with an 1/8" shank that only cuts 1" deep to do this. Anyone have any insight?
It works as long as you understand that a 2" length bit will obviously have more cut reach than the 1". You risk tool holder interference (router/spindle nut) if the depth of cut exceeds the 1" on the 1/8 bit.
The overall length of the 1/8" bit was 2.5" so I think I should have enough clearance if I am only cutting down 1.5". Thanks for your response
You might also get some rubbing on the shank above the cutting length. I’ve done this and seen that, but didn’t bother me much. Was observed on the tool and not the part in my case. As long as the tool isn’t super expensive, I think it’s worth a shot. Sounds like this may be a cost reduction effort anyway 
I know there are long reach tools out there that neck down after the cutting length for this type of application specifically, but 
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I do a lot of cut outs that are 1.5" to 2" deep and using the .25" bit takes so much material and I have to screw the work piece down because it is so aggressive. I haven’t been able to find any .125" deep reach bits that cut that deep so I thought this option would work and be a little safer. Thanks for you input!
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What’s your depth of cut?? How many passes are you taking to get through that thick of stock?
I am cutting a depth of 1.5" for this one with about 17 passes. I supposed I could go with more passes as well so it is taking a little less material.
Did you see this? I found it pretty interesting. I haven’t done anything this aggressive on the 1F, but people are out there trying cool stuff!
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Yeah - that seems pretty aggressive. I get my new bit tomorrow and will give it a try. I mostly cut black walnut and definitely see a difference in cutting end grain vs face grain as well.
I’m doing something similar but what I was really is a long reach into some pockets where 1/4" (even if it’s long) would be too wide to give me the detail I want. So I looked all over. Including this place: Link that has a huge selection but that is also well-organized. (Easy to search.).
However, what I finally found happened to be on Amazon (yeah, I know…) and they will be coming next week. Link. I had to buy 10 of them because they don’t come individually. But they are 3" long 1/8" ball end mills with a CL of 1". So, I’ll have to use a step-down collet converter and go really slow but I’ll be able to have the reach. Naturally, deflection is an issue but I’m hoping to just keep the speeds low.
I have also cut some deep perimeters with 1/8" bits that have CL’s that are a little short. (Wastes less material and is easier to hold down as you say.). When the shaft above the flutes rubs against the wood it might burn a little bit but not the end of the world because I’m going to sand anyway. On metal, I believe it’s quite a different story.
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Thanks for the insight! I will check out your links!
