[Wade Congdon]

Originally Posted by Sun Tuned

I do have one reservation about it though. I'm a worrier, I admit it. So take this for what its worth. The thing about a 1/2 inch bit is that I think when you get done that the hole will be slightly larger than .500 even if only by a couple thousands of an inch especially doing it by hand I would think. When you get done you don't want it to wobble on the shaft because if it does It will do same inservice and that we don't want. Would eventually make a nice wear pattern on gear from oscillating around some.

This is exactly correct. A straight reamer is the way to do this. (Carbide if possible) Best way is in a lathe with the reamer in the tailstock. If you know someone at a machine shop this would be a 5 minute deal for them.