Holes with interrupted cuts / offset holes, how to cut?

[Bentworker]

I like the annular cutter idea, if I come across any for a good price I'll have to get some.

[BadDog]

Those get quite expensive for typical home shop use. But they are wonderful when combined with a mag drill for structural steel work (trailer/truck/car frames, etc). For use on fixed machinery like a mill, unless you do a lot, or have a very specific need, end mills (and/or boring heads) are far more economical and flexible.

[rudd]

OK, I get the torque transfer in straight line accel/decel situations, I'd think the hub would be under a good bit of stress on hard cornering. I don't believe I'd take that job in my shop.

[Bentworker]

Yeah, those annular cutters are not cheap, especially the 2” depth of cut ones! I had access to several 1” depth of cut ones, but not anymore since I switched up employers.

[GlennW]

Don't neglect to consider the sharp corner that an annular cutter would leave at the base of the bore if used in the context of this thread.

A boring bar can be ground to leave a suitable radius to help eliminate stress risers.

[johnfreese]

I would drill the holes undersize and follow with an end mill to guarantee the finished hole did not drift. For the counterbore I probably don't have the correct size endmill so I would check my stock of counterbores. If none of them were the right size I would use a boring head.