I can't believe its been over a year since I posted this. But here's how I make them, maybe it will help. I drilled my thru hole 1 1/4" because I don't have 1 3/16" bit. The rim on the bushing fits snug in the recess so there has'nt been any problems. Only thing I do different now is counter bore, rather than counter sink the mounting holes. Sometimes the guide needs to be perfectly centered and this allows for some adjusting.
http://www.routerforums.com/guide-bu...pc-guides.html