Had a hardwood plug finely machined to precisely fit existing rudder tube diameter. Same plug had hole precisely drilled thru. Placed a long very straight rod inside a larger hole drill (1/2" larger than existing tube diameter). Using rod as guide I slowly drilled up and enlarged the rudder tube diameter. Only had to carefully fair upper end with Dremel before installing new Delrin insertions.
Was about 10 years ago and honestly to this day, don't know where I got the cojones, luck and ability to pull it off... -----Original Message----- From: Matthew <wolf...@erie.net> Sent: Monday, November 23, 2020 10:06 AM To: 'Stus-List' <cnc-list@cnc-list.com> Subject: Stus-List Re: rudder post fitting David: I'm guessing the rudder post is 3 inches or so in diameter. How on earth did you drill out the bushings? -----Original Message----- From: David Risch <davidrisc...@msn.com> Sent: Monday, November 23, 2020 10:01 AM To: Stus-List <cnc-list@cnc-list.com> Subject: Stus-List Re: rudder post fitting Matt...my 1981 40 has a similar configuration but bolt and wheels are oriented athwartship. I also put in new bushings in my tube by drilling out just enough for a new insertion. Was not easy but even my crude machinations seemed to work. October is the time to show your appreciation with a small contribution to this list to help offset the costs. If you want to support the list - use PayPal to send contribution -- https://www.paypal.me/stumurray Thanks - Stu October is the time to show your appreciation with a small contribution to this list to help offset the costs. If you want to support the list - use PayPal to send contribution -- https://www.paypal.me/stumurray Thanks - Stu