I recently started a new project: Designing my own DE safety razor! Woohoo! I plan on using the Zen to cut some really basic prototypes, with my final rendition being made in Stainless or Gold plated brass via Shapeways.Com.
My first prototype was made from foam signboard. This stuff is cool, it cuts like butter (or foam...) so you can set you DOC extremely deep. BUT it also has incredible strength properties and can show some fairly fine details.
I used an 1/8" ball mill and 1mm ball mill.
Ive decided that we really need to come up with an ultra low profile vice. As you can see, I simply did not have the room to clamp the part from the top. So I beveled the eddges and clamped the sides at an angle. This sort of works, but I was not able to flip the part to mill the backside. Ive seen low profile drill vices, but I only have 2" of clearance, and that just isn't enough room.