I used Doug Ross's plans for the basis of my V-block. My vise for the mill is a 4" width so his plan looked quite good.
Here are Doug's plans:
I made changes to the plans since I wanted a "soft" V-Block since I plan on using it with
aluminum,brass and plastic. I also "cheated" on the vertical grooves since I had a nice new
carbide 2 flute router bit with a nice 45 degree angle. Much faster than the way I made the long grooves.
I also have two nice V-Blocks that I set vertical in the mill for working on the end of parts. What I really
needed was the long grooves and that is why I built Doug's plan.
For the long grooves I used an end mill and flipped the part 180 deg to complete the opposite half. That
works good but it does take a bit longer and the part is a bit harder to hold for the vertical Vees.
I tried not to cut too deep since it is just aluminum but when clamped in the vise it should work fine.
Thanks to Doug for the fine set of prints and instructions for making a very useful tool for the shop.