It gets better, I actually screw up and it's documented....
So I get the counterbores in (mistake #2), and right away saw that the 3/8" thickness, (and 3/4" finished length) on the workpiece was a mistake. There's not enough material between the counterbores and the 3 edges of the material as you see in the pics.
This wouldn't be a terrible issue, but the radius on the finished part makes this untenable. There's just not enough material there to provide the needed strength I want in the finished product. This is where I realized that this was just a prototype, and revision 1 was in order.
This was further confirmed when I attempted to finish the workpiece anyways, and the HSS slitting saw I was using self-destroyed when the tool steel work hardened. (AKA mistake #3)
Oh well, back to the drawing board, on to Phase Two. I'm in the process of doing a revised version, stay tuned.
*To be continued....*