"Ron Hubbard" wrote in message
...
Does anybody know how much you can bore out a 1" dia. 6061 aluminum rod
before it
loses it's structural integrity
and either bends or breaks?.

Ron, since you can readily obtain 1"o.d. aluminum tubing in 0.015" wall
thickness, it stands to reason that with careful centering and light cuts,
you could go down to 0.005" or so. You'd have to bolster the chucked end,
and you wouldn't be able to work with much overhang.

LLoyd