At the encouragement of another forum member, I'm not giving up on live tooling for the joint and A-joint pins. In the spirit of my frugalness (Firefox spell checker says that isn't a word) of course I made my own thread mill. Which is a shame, since I already owned two.
Here's the long skinny one attached to my Proxxon rotary tool. It wobbles around too much, and has a tendency to slip in the chuck, no matter how hard I tighten it. I'm giving up on this one. I'm not saying the problem is with the bit. It could be my rotary tool.
Here's the one I just made today. Cost me about $3 for a piece of 1/4" round HSS tool steel, and a fair amount of time on the grinder. It spun pretty straight in the drill, but I was afraid what would happen when I spun it up to full speed in the router. I stood back with safety goggles on when I flipped the switch. No vibration, no wobble, perfect!
Here are my three thread mills. Top to bottom, the one I just made, the one that I'm giving up on, and a Micro100 carbide one. The Micro100 works great, it's just too short!
Haven't tested it on wood yet. I'll probably do that tonight or tomorrow sometime. But I expect it to work pretty well. I'll probably have to clean up the profile of the cutting teeth a bit. I burned out my rotary tool trying to use it as a tool post grinder to grind this HSS bit (doh! I guess I should add that to the cost mentioned above), so I had to shape the teeth on the bench grinder, which isn't very precise. But we'll see.
Thanks for watching!
-- Kevin