Methods for parting off larger diameters

Anyone have any slick methods to glue aluminum back together?
I still have a chunk left, but not deep enough to remake this part.


The part that too short (referring to the drawing) is the .630" needed for the pulleys. I have .493" left. I don't think there's enough to try and salvage the pulleys. But I wonder if I can figure out a method to thread the pulleys on to the shaft portion...
 
Oh frig... I'll just go across town tomorrow and buy more stock... Uhhg


Classic Shawn move...
 
I'm so annoyed. Lol
Starting out in machining is really frustrating. I gave up on the lathe for a while, I'm on the mill now. Making the riser blocks for the motor mount. Just rectangular blocks. Faced them then was milling them to size. The only sharp end mill I have is a 1/4" that's only 5/8 long. I have to flip the piece around 4 times to face the ends. But a longer tool would save all sorts of time... Annoying... I know the tools I need to do what I want... they're all just so damn expensive!
 
Sometimes the parting tool will cut a cone and make the part too small. It is always worth having an allowance for the cut to be less than square across the face and then face it to length after parting it off.. A parting blade that is not square with the work, or not ground square on the parting blade itself sometimes causes that, and I think a loose carriage can also cause that problem. Sometimes it just happens anyway, even with a good technique...
 
I'm so annoyed. Lol
Starting out in machining is really frustrating. I gave up on the lathe for a while, I'm on the mill now. Making the riser blocks for the motor mount. Just rectangular blocks. Faced them then was milling them to size. The only sharp end mill I have is a 1/4" that's only 5/8 long. I have to flip the piece around 4 times to face the ends. But a longer tool would save all sorts of time... Annoying... I know the tools I need to do what I want... they're all just so damn expensive!

Why not use your fly cutter to square and dimension the part?
 
I bought a 1/2" 2 flute end mill with a 1 1/4 cutting surface. More than enough to face and dimension anything I'm doing right now. I have a bunch of other end mills from the old tool box but the only one that's sharp was a 1/4" 4 flute.
 
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