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Hi DougW,
You didn't say what you are building so I don't know if any of these ideas are possible.

1. You could cut tenons on the member to match the largest bit you have.

2.If the above isn't possible, you could make a template and use your router with a guide bushing and a spiral bit and route it out. If you need help calculating what size bushing and bit to use Reible posted a calculation chart some time ago. http://www.routerforums.com/showthread.php?t=163

Let us know how you made out.

Chuck

 

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Hi Doug,
I just installed a new shoulder vice about 3 weeks ago on my bench. It has 2 guide bars with guide bushings that are inset into the shoulder of the bench. The guide bushings are about 2 3/8" dia. , but have a flat on one side. With that flat, I couldn't drill it out with a forstner bit. I free hand routed the rebate to depth as close as I could get to the layout line, and then finished it off with a carving gouge of approximately the same sweep.
If you don't want to but the bit, you might try the free hand routing, or routing around a button template with the right size guide bushing to give you the required diameter rebate, then chiseling out the center.
I hope you have a better experience with your vise than I did mine. I bought the economy model from Woodcraft. It turned out to be a Chineese made copy of a real vise. What a piece of junk. I had to rework all the holes and the screw just to get it installed. That's what I get for trying to save a little money.
Good luck........Chuck

 

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Glad to hear you got-er-dun. Now, don't forget to check the top for flatness. If you don't already have them, that will give you an excuse to make a pair of winding sticks. That could be your first project.
Enjoy it.......Chuck