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There is a 6mm deep groove along the flange on the face of the dropout. The contour tool path machining the flange sides went too deep. I just didn't spot it as I didn't run a simulation before machining. Basically a rushed job and my mate who assisted me (my first time using Fusion 360) didn't pick up on it either.
Mega shit!
Cocked up machining tool path... £20 out the window :(
Lesson learned. Remachining in late Jan. No fixie for hard day in Jan