I'm working on installing my Benchcrafted leg vise. Part of the install is a 1-1/4" hole through the wood for the screw, but also on the leg I need a 2-3/4" wide by 1/2" deep mortise for the bushing. I don't have a forstner bit that size and am trying to wrap my brain around how to use my router instead.
I've got the following rockler bushing set https://www.rockler.com/router-guide-bushing-kit which has a variety of bushing sizes in it. I'm thinking I could use a hole saw to drill a larger hole into a piece of plywood and then use a bushing and bit to route the mortise. But, how the heck to I back into the appropriate sized hole saw and bushing/bit combination? Looks like my largest hole saw bit is currently 3-1/8", but I think I can find additional hole saws easier than a forstner bit larger than 2-1/8.
Template Guides:
- 1/4" (inside) x 5/16" (outside)
- 9/32" (inside) x 3/8" (outside)
- 11/32" (inside) x 7/16" (outside)
- 13/32" (inside) x 1/2" (outside)
- 17/32" (inside) x 5/8" (outside)
- 21/32" (inside) x 3/4" (outside)
- 5/8" (inside) x 51/64" (outside)
If I were to proceed with the 3-1/8" hole saw, my math says that I would need to have a 3/16" spacing from the guide that it would make. That way, the resulting hole/mortise was 2-3/4". How do I know if one of these bushings works? is it the difference between the bit cutter and the outside of the bushing? Using bushings for something like this will be a new skill for me, so any help appreciated. Thank you.