bran kulez wrote:The next step would be to draw a 1.0 mil stylus and insert it into the groove as Ld suggested. The exact location of the 1.0 mil diameter dimension on the actual stylus tip, the angle of the cone and the radius at the tip of the cone seem to be the crucial dimensions. Any input would be appreciated...

All good stuff, BK here's some input to Help draw the stylus.

The stylus ball end is a half sphere, and you know the radius is 1.0mil. It will contact the groove walls where the tangent on the circular section is exactly 45 degrees, the groove wall being at 45 degrees. This is the big clue !

Above the half sphere, the included angle of the cone is between 40 and 55 degrees.

Prepare to be amazed, BK, and remember those groove dimensions are abs min, not typical !