Bruno wrote:
I was trying to put a 1.125" hole through a piece of steel that's 1.5"
x 2.5" x 1". I was using a mill and the only 1 1/8" cutter that the
shop I was in had. It made a really lousy rough cut that's also about
.012" oversized. This piece needs to be split to clamp down tight on a
1 1/8" post.

Anyone have a suggestion for how to fix it up?

I've never used JB Weld... would it work to line the hole with that
and then bore it to 1 1/8"? I've made a jig so I could put the piece
on the faceplate of the lathe to bore it there; I may not have access
to a mill for quite a while now, so a lathe approach is best.

I was also thinking about a sleeve, but I'm not sure if there is
enough room to bore it out to fit a sleeve in there. If I did, what
size OD on the sleeve would work out? Or should I say, how thin could
the sleeve wall be?

Last resort is to smooth the hole out as well as possible and then
slit it much wider than I had planned, but that's not the best way.

Thanks.
-Bruno


Slit it, lay on some weld in the bore, or get it metal sprayed, clamp
the two halves together with an appropriate shim (the thickness of the
saw cut) between them and BORE it (correctly) this time.

All of which may be "gilding a turd". I'd try it as it is and see
whether it clamps enough to do the job, "Pretty is as prety does", 'yknow.

Happy Holidays,

jeff

--
Jeffry Wisnia

(W1BSV + Brass Rat '57 EE)

"As long as there are final exams, there will be prayer in public
schools"