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This it what I would do. :) with a plunge router ....

Core Box Bits
http://www.mlcswoodworking.com/shopsite_sc/store/html/smarthtml/pages/bt_core.html#Round_Nose_Anchor

V-Groove Router Bits
http://www.mlcswoodworking.com/shopsite_sc/store/html/smarthtml/pages/bt_sign.html#V-Groove_Anchor


You can also use a Brass Guide with a template, If you Have A BIG one and your router can take on a big one...( 1 1/2" OD ) but if not the jig works well for this type of job, you can also put a counter sink slot in the jig so you can adjust it in or out, so you can use it for other jobs as well .





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Hope it helps

Bj :)
 

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