The new boring bar nearly fits inside the throat of the engine but is small enough to cut the entirety of the convergent nozzle geometry. The only downside to this new boring bar is it is small; at only .25" in diameter and cantilevered out approximately 3.5", it is vulnerable to flexing under cutting loads. This could damage the tool and/or the part. To mitigate the problem, shallower cuts were taken. In all, the machining process took more time but it was done without a major issue. The only problem that was seen was there seemed to be a resonance frequency reached in the part that machining a pattern into the combustion chamber wall in one section. For future reference, the speeds, feeds and rpm's can probably be changed to resolve this.
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