I have been using an Akeda dovetail jig and just ruined the guide bushing. It is marked 0.438", which is the exterior diameter. I can pay $25 ( 1/2 is shipping) or use an old Porter Cable bushing which varies about .002 to ..003 in diameter as you go around it with a micrometer.

I find it hard to believe that that .002" variation would be a problem. Anybody had this experience and how did you resolve it.

Thanks
Len