"Ed Huntress" wrote in message
...

If straightness is an issue, ball-sizing or hard-honing are not going
to do it. They're good for roundness, and ball-sizing is good for
diametral accuracy. A huge bar holding a hard Sunnen hone would give
you the straightness, but now you're talking some pricey tooling. The
hard hones, unlike the flexible ones, make their own path. They don't
tend to follow the existing bore.

Boring has an advantage in achieving straightness and roundness, as
long as the boring bar's flex is minimal.

--
Ed Huntress

Maybe cobble up a twinbore something like this:

http://images.craigslist.org/5Q55U15...f0626d1c29.jpg

Could solve the deflection problem and help with chatter. The finish should
be adaquite for honing. When i have some tinkering time i want to make a
set.

Best Regards
Tom.