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To create a perfectly symmetrical shallow cup on a W-Y I’d need a rotary burr roughly the size of an ovalized softball…Can’t find that at MSC or Grainger. Instead, I thought I’d try to make a tool similar to what Numbskull mentions above.
To get the dimensions of the W-Y’s oval face, I placed it flat on a sheet of paper and traced the outline; ran it through a scanner and put it into Excel. I copied the oval and scaled it up to the size of the softball. If this really were a cutting burr, only a very small area on the outer edge of the oval would be used in the cutting, so I took that very outer arc and made a Vega template out of it. I used the template to create a hard maple turning.
Assumedly, this is the exact shape to cut a symmetrical cup into the face of the W-Y. The hard part is adding an abrasive surface to it; I tried hook & loop sandpaper that seems to word for foam-backed sanders but it “gave” too much during shaping and wasn’t durable enough to handle sanding birch.
I'll probably mess with this a little more but then park it for this winter. I can live with the shallow but asymmetrical cup from the carriage bolt on the few large poppers I need to finish this season. Running out of build time.
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