Overall I think one one thing I might do is cut the grooves staight after turning the rim flat across. That way I can offset from the centreline joint (as per the instructions – which worked pretty well for me during the trial run), and then if there’s a discrepancy at the end of the process, I can face off from each side of the wheel to make the end grooves equal distances in. I already know I have to do this to some extent, so it seems to make sense to do it last rather than first, to reduce my options to correct.
Going back to the tool holder – I have an R/T so I could possibly use that in conjunction with my 1mm milling cutter to make it?
Not withstanding Jason’s comments about stiffness – I wonder If I could make it out of round bar, with a flat milled on the end, to fit in a hole drilled in a much bigger bit of square stock?
Still doesn’t get me a 1mm wide groove tool, but at least it’s something.