Step #1: Clean up the aluminum Prev Next Take the rough bar, and trim it to 4" x 5/8" x 1/2". Dimensions aren't very critical in this project; if you have a 5/8" x 1/2" bar, just take a very light cut off each side to make it look nice. Step #2: Mill a groove Prev Next Mill a 0.25" wide groove 0.25" deep. It should be in 0.10" from one edge. I'm using one of these chip shields in the second photo. Notice the pile of chips behind it and lack of chips in front. Step #3: Drill the set screw holes. Prev Next Cutting the groove in the last step created a thin side and a thick side. These holes will be drilled through the thick side. Spot, drill, and tap three holes 0.125" from the top, at 1", 2", and 3" in from one end. Step #4: Attach magnets Prev Next Drill two holes on the bottom with a drill bit the same diameter as the magnets. Don't drill all the way through, just deep enough for the magnets to sit flush. Glue in the magnets with J-B Weld or another suitable glue. Make sure they are perfectly flush with the bottom of the part.
Step #5: Cut and insert plexiglass Prev Next Cut a piece of 0.25" thick plexiglass. Make it whatever dimensions best fit your machines. 4" x 3" is a convenient size for me. Slide it into the slot, and insert three 6-32 setscrews into the holes you drilled and tapped. Stick it to your machine and enjoy! This cannot replace safety glasses, nor is it meant to. It just helps reduce the amount of swarf flying at you.