I got to work on the little model car I've been programming and made really good progress on it!
I spent the extra time getting the program as clean as I could before running anything. This included sorting the tools and ensuring they all had the correct preset for the F&S according to the roughing vs. finishing pattern.
I ran into a weird issue where the post-processor wouldn't work correctly, and I kept getting errors on one of my 5-axis moves. I eventually narrowed it down to one specific toolpath with an odd angle, but the axis orientation was correct. I played around a bit I figured out that I had to add the machine I was using in the initial operation setup, which I haven't had to do in the past. After selecting a Haas A+B machine, it posted fine.
My boss had me sit by the machine while running the new program with the rapid at 5% and reduced feedrate since I haven't done a ton of 5-axis work before. I'm very glad I did, too, because I was able to catch the machine before it plunged into the big 5-axis trunnion.
I'm really glad I've been writing about my experience and troubles I've gone through in the past, and because of it, I was able to quickly fix the problem and get the show on the road (no pun intended).
The process I'm going about milling this part out is slightly different from my previous method, and I'm taking some of the ideas afforded me by my boss and brother to put the programs in sections with their own tools. Basically, having a different endmill for a roughing operation vs. finishing. I'm also taking advantage of using a shell mill to rough out a good portion of the material before switching to a 1/2" endmill.
Overall everything has been working extraordinarily well and I'm really pleased with the outcome thus far!