I used Carbide create and did it in 3 passes.
I loaded the EGA as a jpg.
Created an outline of the EGA 1/4" outside the jpg.
Created another outline 3/8" outside the first outline.
Pass 1 Cut the pocket using a pocket using a 1/4" endmill .400" deep on the inside of the first outline.
Pass 2 Used VCarve tab to carve the EGA using a 20 degree v-bit. Starting depth was .400", max depth .500"
Pass 3,last pass, was to cut-out the tray using a 1/4" endmill on the outside of the 2nd outline.
I used 8 tabs and I also taped everything down with some good double-sided tape.
I used a handheld router to round-over the bottom edge and cut the relief for the base.
I had planned it to be a catchall tray for my friends dresser, but his wife liked it so much it now hangs on the wall in their family room.
USMC Catch All.c2d (1.1 MB)
If looking to make many gifts easily think of the attached catchall tray I did for another marine friend.
It was much easier.
USMC Catch All with name-2.c2d (1.2 MB)
If anyone knows how I can improve on any of these please let me know.
I need to learn more.
Bill
