the holes are center-punched, then center-drilled, then they get the full Q bit. the issue with using a flat bit is its still a really small area that it first contacts, and since its circular, if its off like 1mm on the horizontal its off like 2mm due to the curve.
i might be able to smooth out the surface really nicely by skimming it down with the end-mill a little bit, then the punch and centerdrill would have a nicer bite and wouldnt magnify any mistakes, but its still one more step on a different machine and i want to see how much time these will take before i make the final call. worth considering though - thanks for the idea