The picture on the right is the material after my first attempt of OP2.

Issues: 

• Actual thickness 1.012, is greater than target thickness 1.010.

• Chamfer tool did not touch the material during operation.

• Unfinish sides.

Solution:

• Check Z offset, if correct, lower it.

• Check fusion setting????

• Chamfer: I selected the higher edges, changed to lower edges.

• Chamfer diameter was incorrect (0.25),  changed to actual size 1cm.

Above not working

change Chamfer tip offset from 0.06-0.1in 

!!!wrong hole size.

use major axis for threading. My model hole size was set using minor axis, the drill in the machine is 0.3465.

CRASH

Model modified before program, started machine at rapid 100%. Tool crashed into Kurt. Found out that WCS was unintentionally set at the top. 

Done.