I think if you use an extended length drill bit, you could try the following as an alternative method (and it should be dead safe to boot, you are scaring me with all the router talk!):
1. chuck it up as far as it will go
2. drill down 2"
3. without retracting- stop the drill press
4. lock your quill
5. loosen the chuck- watch out, as the drill will get hot.
6. unlock your quill
7. tighten chuck at the top of the quill stroke
8. drill down 2 more inches
9. repeat until you are through
I would clamp both bits of aluminum bar to the top, to become an ad hoc guide bushing for the rest of the operation.
You may need to hack the extended bit to an appropriate length, depending on your drill press. |