PSA: started touching off with a piece of paper instead of eyeballing it
For years I brought the tool down slow and watched the gap, and I was off by a few thousandths every time. About 4 months ago a guy running a VF-2 in Fort Worth told me to slide a strip of notebook paper under the tool and creep down until it grabs, then set my offset there. The paper is about .003 thick so I just subtract that and I'm dead on, and I haven't nicked a part on a setup since. Anyone got a better feeler trick for small end mills, or is paper pretty much the standard?
How many of you have had that "why didn't anyone tell me sooner" moment with this stuff? Man I feel your pain on the eyeballing struggle, I wasted way too many setups thinking I had a good eye when I really didn't. Paper works great for the bigger tools but on tiny end mills it can be a real pain since the paper wants to push the flutes around before it grabs. For small stuff I've had better luck with a rolling paper or a zigzag feeler since you can feel the drag way lighter than with notebook paper. Honestly though the fact that you haven't nicked a part in 4 months says plenty, if it's working don't fix it.