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Seems like when the bushing is installed in the cap there would be a blind end and only 1/14 inch deep. Don't think a brake hone would work well here. Right tool for the right job is the answer.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.
Actually not as long a time as you would think. Also using a good "cutting" oil prevents the stones from clogging with the brass. I've used this technique many times. Just recently used it on one of my steering gears after replacing the sector shaft bushings. As far as the "hourglass" effect, if you use proper hone technique and also check your work regularly you will prevent this from happening. Once your close to the proper fit, you would install the bushing on the shaft. By turning it on the shaft you can see your "high" spots and then hand sand them down. Yes it can take a while. It took me an hour to hone out my steering gear bushings, but it can be done and the finished product is usually excellent !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.
Actually machine shops use a power "hone" to fit parts like this all the time. I put this out there to help those who don't have the extra cash laying around to spend on a tool they might never use again. Using a brake hone with patience and care "will" give you excellent results. In fact the sector shaft fits so perfect in the bore I did for my steering gear, that there is not even 0.0001" lateral movement in it. That's correct 1 in ten thousandths of an inch. Yes it takes time, but if you have no money but plenty of time then this will work.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 hole is already there. Using a reamer with reasonable care it will be to correct size and straight. Yes, things can be done without the ideal equipment but without knowing the OP's circumstances and skill set/patience level I'm not putting info like that out there as I don't want to get them frustrated or have them waste time, parts and money.
Got the new bushings pressed in last night, need to remove about 0.010-0.012” off each one.
I found an adjustable reamer for $39 on the famous auction website. When I’m done I’ll lend these out to anyone that wants to borrow as long as they pay the to/from shipping. Also found one for the spindle bushings.
I do like the brake hone idea. I thought about that too. I have one for the brake WC’s but it’s too large. That would be a good way to get there also, and have a smoother finish.
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