Cutting stock for the bezel
Faced flat, turning outside diameter
Turned down to largest outside dimension
Ridge for hex flats cut
Two decorative grooves cut
Chamfer cut
Center drilling for removal of center material
Drilling through with a 3/8" drill
Then again with a 5/8" drill
Boring out to the various internal diameters needed
More boring
Internal boring done
Cutting internal threads for mating with light engine and battery tube
Parting off the piece
Progress so far
Chucking it back up by the tail end
Facing flat
Setting angle for front chamfers
Outside chamfer cut
Inside chamfer cut
Transferred over to rotary table on mill, cutting flats
Cutting crenellations
Cutting round grooves with ball end mill
Gavin vacuums up the swarf (he did some of the cuts too but I was too busy guiding him to take pictures)
Bezel done
Chucking up stock for the light engine
Turned down diameter for threads, now turning the smaller diameter above them
Ready to cut external threads
Milling out recess for driver board
Threads cut, driver board recess cut
Ensuring that driver board fits
Parting off
Rotary table mounted flat, centering it beneath spindle
Milling holes for wires to run from driver board to LED
Milling channels for wires
Wire holes and channels done
Drilling holes for LED screws
Tapping holes for LED screws
Light engine flipped around, milling holes for screwing it into bezel with pliers
Light engine done