Thanks for the comments so far everyone.
Doing a custom keycap in metal, for a first custom?! That's pure flash!
Very nice looking, light years ahead of my first attempts. 
ty, Metal is what I am used to, anything else would have been more exotic
* CPTBadAss gives raucous applause
That's incredible. I can't wait to see where this goes. Great work.
I do have to know though, how steady is that mill? Sounds a bit challenging to use.
I stripped the crossvice (cheap chinese, $90 for 6" vice, 8 inch movements) and polished all the slides and everything else I could, filed a few rough corners. That helped a lot, I also made a 2 piece custom base for the vice, wood with 3mm neoprene base. There is very little play in the axes of the vice, only small amount when reversing direction. Sounds peculiar not to bolt it down maybe, but the 2 piece is so that I could either have the vice freestanding with both base pieces, or use half the base and use the workstation base as the second half. As a result, the Dremel and vice are quite firmly bound together, which took out a lot of the erratic behaviour.
The main wobbles now are on the workstation side, but in a fairly predictable way, it will grab at anything like a corner, and its worse cutting with the rotation rather than against it. I have already replaced a few bits on the workstation with brass, and it could use a few more, also there is one piece of cardboard wedged in the top which reduced a great deal of the play, I must make that a 'permanent' fix sometime. When it does have play, its usually along the X axis as sat in front of it, so it became fairly easy to make the least important part in that direction. I also left the really fine detail to hands. For much of the routing of the undersides, I just drill the basic area then use an endmill as a shaver to trim thin slivers off, its pretty safe for that.
tldr; yes, its insanity, don't try it
whelp... sculpting in epoxy now looks like child's play D:
Hehe, I watched your work with increasing flabbergastedness, you have produced so much good work so quickly. But as I am a ham-fisted non-artist, the advantage of the metal is that when I slip and carve the wrong bit (about 1 time in 5) it does relatively little damage so I get away with it. The downside is the details can really burn hours, but hours I got
