I bore the holes after the pieces are complete. My sets have various
diameters at the bottom. I took a 2x4, bored holes , sliced in half
along the long side. Then bored a hole on each end for a bolt and wing
nut. Place the chess piece in the jig ,tighten wing nuts ,bore on drill
press.When you slice the 2x4 in half you slightly reduce the hole
diameter, this helps hold the pieces tight.
I punch 1/4" holes in sheet lead with a whitney punch.I bore the
bottoms with a brad point bit a fraction larger. Drop lead into hole
and tap it with a 1/4" punch.Depending on the length of the chess
pieces I usually bore from 3/4" to 1 1/4" deep.
Bore the holes in the jig with forstner bits, you will get clean holes
that will not scratch the chessmen.
mike