Hot Damn---I learned something new today!!! I had to slip across town to see a customer (well actually, it was so nice I wanted to get out for a drive in the roadster). While I was down in the south end, I decided to stop at BusyBee and buy a knurling tool, as they are on sale. I believe that I only tried knurling once before, in grade 9 machine shop, and it was a disaster. ---Anyways, I paid $25 for the knurling tool, and did a big search on my machining websites to gather information on how to use it. I had a 2" length of 1" diameter aluminum scrap, so I chucked it up and ---Voila---It worked like a charm.
My real motivation was to be able to make nice, machined aluminum peices with a 1/4-20 thread in the center and a knurled outer diameter to hold the new Lexan windows into the hotrod.