Hi John,
I was planning to clamp the frames together and mill both slots at one setting. The outer edges were very easy with a file not hard at all. The overall finish of the raw castings was about as smooth as a bear's bum.
When did Stuarts ship your castings?
In any event they should replace them if they will not machine nicely, they have always had a good rep for replacing any dodgy castings. I was going to send mine back, but given they seem easy to work, it's simpler to put a but of extra effort in to cleaning them up.
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Steve