Need some advice

[thedave]

I need make a 5/8" hole through the length of a 3"x 1"x 1" 6061 aluminum bar. I will be inserting a 5/8" x 3/4" bronze bearing into each end. I am looking for the most efficient way to do this. based on my research, drilling is not precise enough, so I have been looking at using a boring bar or a reamer. As I have no experience with either, I have no idea. I will have access to a mill and a lathe. Thanks.

[kling8]

Depending on how precise you want the hole, drilling then boring would be the best, reamers get you really close to. I have indicated in the reamers to make them more precise. both cases you will have to drill the hole undersize first, reamer is easier, maybe a bit faster, but boring is going to be most rigid.

[packrat]

Reaming should be good enough. Most bearing bronze bushings are made over size on the OD. to be a press fit. Ream it clear through in one set-up. After you press in the bushings you might(usually) have to run a shaft size reamer through the bushings to size them.

cary

[RICHARD ZASTROW]

"google" jig borer reamers. They got their name from their use on jig boring machines. These machines and the reamers were used where accurately sized holes were placed in accurate positions. Jig bore reamers do not follow existing holes like normal reamers often do.

Dick Z