[Gene Howe]

...to spin a 3/4" straight bit in a PC template guide with a 25/32" ID?

 

[Gene Howe]

I figgered a 64th clearance was a bit tight. PC's bushing is steel and the walls look pretty thick. If I had a machinist cut a 32nd from the inside, do you think that would give enough clearance?

 

[Gene Howe]

How well can you center the guide? Can you somehow have the bit protruding out of the guide so only the shaft is within it?
Out of curiosity what is the OD of the template guide?

I'm cutting 3/4" holes using a template with 1" holes. So, the OD of the guide bushing would be 1".

 

[Gene Howe]

Found a 1 1/4 OD PC bushing that will work. Just need to make the template holes bigger.

 

[Gene Howe]

I knew you would figure it out. That is what I was going to suggest.
Herb

The bigger OD is no problem but, I just got lucky finding it. Only Klingspor had one of all the sellers I found.

Don, I couldn't find a brass one that size.

 

[Gene Howe]

Electric drill, piece of dowel, and emery cloth, should enlarge the hole easily enough.

Thanks, Theo. That would have been the next thing to try if I hadn't found the bigger one. It's 1 1/32 ID. Just needed it to be big enough to spin a 3/4 bit safely. Not following a pattern so, OD isn't critical.

 

[Gene Howe]

Thanks, Harry. I'm just cutting bench dog holes. The reason for the template guide is to be able to use a template that assures accurate spacing.

 

[Gene Howe]

Thanks, Tom. Definitely worth consideration.

 

[Gene Howe]

A plunge router using a plunge bit makes the cleanest holes.

My thoughts, too. Plus, quicker.

 

[Gene Howe]

I am new to routers but I saw a video where someone was using a bushing guide and template to drill 1/2" holes with a plunge router. I thought that was amazing. Then he showed using same bushing guide and 1/2" bit to drill 3/4" holes with a 1" template. Would that work for you?

dmac257

It definitely will and that's exactly my plan. Thanks.