Any help in finding a way to drill for the 3/8 size bushings?

I know StewMac has special sized reamers but there must be a way without them. Of course a 3/8 Forstner bit is too big and next size down is...

Tried 32/64th twist drill but tear-out is nasty.

Thanks. love reading all the wisdom threads

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yeah, same bushing I think. Wiggle worth a try

A set of needle files are a great and inexpensive addition to the workshop. I use the small diameter round file to finish off the holes for the bushings...and no need to "wiggle" the drill bit.

Use the next size down bit and a tapered reamer to bring the hole up to size. 

Tapered reamers run about $10 to $15 around here at the hardware stores, $2.99 at Harbor Freight.

Sharp drill bits, proper speed and masking tape help prevent tear out when drilling.

I use the next size smaller drill bit and then a tapered reamer to get a tight fit. Like Robert Jones is saying, you don't need a "special" reamer from Stew Mac.

Ditto on also using a round "rat tail" file to assist.

If you make the hole too big, you can wrap a little tape on the bushing to make it fit tighter again.

Thanks all.

Found a couple of reamers in retired tool drawer that together get me close. Reamers not quite sized right so finished using the split dowel sand paper strip trick. Actually can get pretty precise with it.

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