BMac,
Do you really think taking 0.01" off the diameter of a 0.75 endmill is gonna make a big difference stiffness wise?
I've used this method many a time to great success. It really depends on the spec of the hole. How round does it have to be and such, and the capability of your machine. If you have trouble with the machine repeating after a toolchange, not even a boring head will help your application. If you are confident that your tools repeat in the spindle, then boring head all the way.
Iscar ITS boring system is the cat's A$$. Sanvik's system is pretty good. D'Andrea makes the same system as Iscar, but it might be cheaper. I've seen the techniks system in some trade mag's, but I've never used them. Iscar and Sandvik are pretty much set it and forget it. If you have good machining parameters.
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