Precision Manufacturing with Mini Mill

[topgun]

Couple of thoughts here:
An endmill or reamer that size is bigger than what the machine can handle, so then you go to something that can cut big without the stress on the machine. That would suggest a boring head. https://littlemachineshop.com/produc...3662&category=

You have a DRO, so unless it's damaged, you should be able to travel from your starting spot to the various spots you need to drill, bore pretty accurately.

Poor Man's Way:
Draw up your part in SolidWorks (or some other CAD tool). All are available free to the FRC teams. Print the drawing on a laser printer (not inkjet). Use the printed drawing as a template and transfer punch the hole centers through the paper to the work piece. Then mount in mill and drill out or bore out the holes. If you are careful, this method is pretty accurate, though the DRO will be more accurate.

Another thought is to have a machinist (retired or working) volunteer to show you and your team how to do this one night on your mill. They would probably get a kick out of it. Then practice. Taking your time and being careful can lead you to pretty good results.