Things all fell in to place when the decision was made to follow in the McWire's footsteps and exclude the mill from the build process. This made the part less time consuming to produce and more in keeping with the original design objective.
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The process being relatively straightforward: a sharpie was used as layout dye, a sharpened TIG electrode was used as a scribe, a compass/dividers and automatic centerpunch were used to locate holes relative to the scribed tracing.
Only two of the four holes were located in this method, with the other two being laid out using the very same digital calipers as hermaphrodite calipers to scribe a centerline between the tracing and the edge of the part. None of these dimensions are critical of course as the caliper jaw merely needs to be contained within the hole pattern.(ideally: not directly next to the knife edge)
A vise/drill press, and a 6-32 tap plus tap drill(#36) were used to drill and tap holes for 6-32 all thread. The initial 4 holes were stacked drilled with the #36 bit. All other operations were done individually.
Parts list:
4X 6-32 nuts
4X 1" lengths of 6-32 all-thread
1/4" alluminum plate
Tools:
Drill
Calipers
Sharpie
Tungsten TIG Electrode/scribe/hard pointy metal/razor blade/etc.
Centerpunch
6-32 Tap
#36 Drill bit
#28 Drill bit
Dividers/compass(optional)
The "12" sliding jaw clamp" has become a separate part for simplicity sake and will be fixtured to this part with small cap screws hidden under the 6" caliper jaw.
