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The reamer is THE right way, and cost is reasonable, yes it can be done with a hone IF it doesn't clog, it could even be done with a whipstick/sandpaper in a diegrinder. Will the bore be straight on such a short length? Definitely not. Possibly not even round bc the hone just follows whatever...

You'd be there a while taking out .012", and would wind up with a hourglass shaped bushing using a spring loaded brake hone. Non ferrous metals also clog grinding/honing stones.

Gringeltaube is the king of homemade machine tools!!! A 1-1/8 hand reamer should get it right where you need it according to the specs. Mr.G. Do they give a spec for the spindle bushing ID?

You can get a import hand reamer for the kingpin bushings for $50-$60 on egay, or any good machineshop should be able to ream them to size in a few minutes providing they are not a odd ID. By your first post it looks like the pins measure 1.124 , a 1-1/8" (1.125) reamer is pretty common, that's...

What is dia of kingpins? What is id of bushings after pressing?

I wouldn't want the large spindle bushing snug bc of expansion with heat, it could stick to the shaft as the shaft grows. The spindle bushing won't have anything to do with tire wear or alignment as it is just a guide to keep the shaft straight while spinning. There may be a clearance spec for...

.124 should go in .127, is the .127 ID after being pressed into the holders or before? If before then they are being crushed when pressed and prob require reaming. I'm not a TM expert but have been a machinist for a long time and reaming bushings after pressing is very common.