Mag drill is a bit more rigid, but yeah, you are going to trash them.
Make a jig for the 3/8 endmills using a drill bushing. Might hold things a little better.
Carbide burrs work well for cleaning up plasma cut holes. I use a small one in a Dremel to remove the taper and the hardened surface before tapping holes.
Everything plasma cut has a taper, it’s just worse on holes and small arcs, because of the way that the plasma stream trails behind the torch.
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You could always fabricobble a wire edm to cut through that hard chunky plasma leftover… 
Always better to center mark and cut holes off of a plasma if you need them precise (-ly located and sized), or leave enough meat that you can file / grind through the dross before attempting to cut via rotary tool.
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I had another thought…3/8 hole in how thick? Fabricate a tool steel punch and die and chuck it in the press.
a punch would work if the holes were smaller, with them being on size on the big side a punch would just mangle the part.
I’ve ordered a solid carbide reamer and a carbide tapered end mill. i’l post pictures of the broken carbide when i get a chance to work on this again.
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TAKE IT SLOW, and use plenty of coolant / lube to damp vibrations and wash away the hardened surface material’s chips.
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found a cheap set of chinesium #1 Morse taper reamers, they seem to be working so far. the carbide tapered endmill lasted all of 2 seconds…
I am not sure about that statement…I could have sworn that when I did nesting it moved around to minimize thermal distortion…
@LesNewell …if you are around could you answwer this…
It true went back and checked. I had it set on 4 or 5 inches.
Redid the cam to confirm. It doesn’t work in a nest only a sketch.
Oh and what I see on sheetcam forum. Les seems to have let someone else help with tech. Best I remember he announced his wanting to retire. The guy that helps is also on here too if I am not mistaken.
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