If you are going to cut it in half and use two bolts to clamp just cut
it apart and rebore. If you were just going to do a slit on one side, it
will still work if you can take up an extra .040" in your clamp
arrangement. If you just clamp up once, use a beer can for shim stock.

JB weld won't do it because you would have to have it so thin it will
pull away. If you want a sleeve in there, it can be a loose sleeve but
it needs to be thick enough to have some strength on it's own. In steel
I'd suggest a minimum of about .010" so you would need to bore the hole
out to .020" oversize.

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