I've been making infill planes from scratch lately and need help with a particular problem. Take a look at the steel rivets with brass sleeves fixing the front bun and the rear tote and infill to the inside of the plane in this photo.
To place these sleeved rivets, I clamped the plane to my drill press table and, using a drill bit that matched the diameter of the rivet plus sleeve, I drilled all the way through from one side of the plane to the other.
Then I counter-bored the hole on each side, eye-balling it in an effort to make it not too big, not too small, in hopes that when I peened and filed the sleeved rivets, they would fill in the counter-bore perfectly.
But as the small gap around the rivet and sleeve through the bun shows, eye-balling it doesn't get the job done.
Can anyone suggest a jig or a technique that will enable me to drill a perfectly sized counter-bore repeatedly? It's very frustrating to get this far into a project like this only to mar it, and I'd greatly appreciate some input.
My drill press, FYI, is a Craftsman with runout and an imprecise, screw-type gizmo limiting quill travel. Some months back I bought new bearings in hopes that they would solve the runout problem, but I haven't had time to take the machine apart and install them. But it's not the runout that's the problem, in any case. It's the fact that every time I counter-bore the holes for my sleeved rivets, I end up with a different opening. What's the solution?