This is one that I learned when I first started with a manual mill, and I forgot it when writing my first programs. On the first pass the surface will be rough and uneven, even when cut with a chopsaw. So first pass should be less aggressive on feed rate and depth of cut.
UPDATE: I have had "Millie" running for several hours now cutting the first piece of aluminum to 2.686" wide, then I cut the bottom, the slot, and the side cuts. Doing 0.005" per pass with 1/5 the mill diameter overlap is snag and chatter-free.
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