That would be way too simple, can you complicate it for me?
One catch with virtually any solution using a slitting saw is that my arbor using a 3" saw will not permit cutting through both sides, rotating for the second cut is doable but hard to get very precise with out some form of rigid indexing.
Flange OD is 1.200. Maybe making a small as possible arbor would just let me squeak by it's limits.
Sure wish I could find these to purchase, would save a lot of time, kind of hard to believe I haven't seen any really.
The control block that these go in has to be machined as well so there can be some fudge factor in the final size.