How do I cut this slot?

[finsruskw]

Making an order foe a bunch of "barrel" nuts to secure the bumper jack in the trunk of a 57 Chrysler and only have pictures and a rough sketch to go by. The pictures are not mine and I wish they were using a digital caliper.

The part is of cold rolled, 1.275 x .750 dia. with 1/2 threaded 1/4 x 20 and half drilled .60" deep @ 5/16" dia.
I have them done except for the angle on the threaded end and the slot in the other end.
How do I cut this slot? It is not very wide and the smallest end mill I have is .100"
Afraid it will not last very long as in BREAK!, and will take forever with this approach.

The last pic is what I have so far
The slot is for tightening the nut with the flat end of the lug wrench
Am I reading that caliper right in #2408 that the slot is only about .090" wide??

 

[Cadillac]

A fast way would be a slitting saw.

 

[Winegrower]

Deleted

 

[brino]

Slitting saw on an arbour would be the traditional way.

It could also be done with a saw blade, but is harder to control.

-brino

 

[jwmelvin]

Slitting saw seems best by far. But a 0.1” end mill isn’t so much bigger than the 0.092” slot. For the intended use I don’t see why would be a problem.

 

[mmcmdl]

3/32 end mill . Cheap and easy .

 

[jwmelvin]

3/32 end mill . Cheap and easy .

With that approach, how deep would you advance each pass? A full tool diameter? Less?

 

[mmcmdl]

No reason you couldn't go full depth if the chips were cleared .

 

[jwmelvin]

No reason you couldn't go full depth if the chips were cleared .

Thanks.

 

[finsruskw]

Do slitting saw blades come in different thicknesses?
Are they available as a set or do I have to get the pieces individually?
If I am going to make a number of these it sure looks like the way to go.
And...I would have a use for my new set of collets for the square block!!