<!DOCTYPE HTML PUBLIC "-//W3C//DTD HTML 4.0 Transitional//EN"> <HTML><HEAD> <META http-equiv=Content-Type content="text/html; charset=iso-8859-1"> <META content="MSHTML 6.00.6000.16705" name=GENERATOR> <STYLE></STYLE> </HEAD> <BODY bgColor=#ffffff> <DIV><FONT size=2>I like Jim's plugging method.  Or you could cut a 2 1/4" hole in a piece of plywood as a template and then use a 5/8" guide bushing in your router with a 1/2" dado bit which should leave to a nice neat uniformly deep 2 1/8" hole to mount the caster.  The guide bushing I have protrudes a little more than a half inch below the router base so it would have to be at least a 5/8" piece of plywood for the template.  </FONT></DIV> <DIV><FONT size=2></FONT> </DIV> <DIV><FONT size=2>Or maybe you could just use a thicker piece of plywood than the 1/8" you tried to locate the center and it might not split then.</FONT></DIV> <DIV><FONT color=#000080 size=2></FONT> </DIV> <DIV><FONT size=2>Mark Mc</FONT></DIV> <DIV><FONT size=2>MN</FONT></DIV> <BLOCKQUOTE style="PADDING-RIGHT: 0px; PADDING-LEFT: 5px; MARGIN-LEFT: 5px; BORDER-LEFT: #000080 2px solid; MARGIN-RIGHT: 0px"> <DIV style="FONT: 10pt arial">----- Original Message ----- </DIV> <DIV style="BACKGROUND: #e4e4e4; FONT: 10pt arial; font-color: black"><B>From:</B> <A title=JIMRPT@aol.com href="mailto:JIMRPT@aol.com">JIMRPT@aol.com</A> </DIV> <DIV style="FONT: 10pt arial"><B>To:</B> <A title=nelsong@intune88.com href="mailto:nelsong@intune88.com">nelsong@intune88.com</A> ; <A title=pianotech@ptg.org href="mailto:pianotech@ptg.org">pianotech@ptg.org</A> </DIV> <DIV style="FONT: 10pt arial"><B>Sent:</B> Friday, August 15, 2008 11:50 AM</DIV> <DIV style="FONT: 10pt arial"><B>Subject:</B> Re: modify legs for new casters</DIV> <DIV><BR></DIV><FONT face=arial,helvetica><FONT face=Geneva color=#000000 size=2 FAMILY="SANSSERIF"><BR>In a message dated 8/15/08 11:21:42 AM, <A href="mailto:nelsong@intune88.com">nelsong@intune88.com</A> writes:<BR><BR><BR> <BLOCKQUOTE style="PADDING-LEFT: 5px; MARGIN-LEFT: 5px; BORDER-LEFT: #0000ff 2px solid; MARGIN-RIGHT: 0px" cite="" TYPE="CITE"></FONT><FONT face=Arial color=#000000 size=2 FAMILY="SANSSERIF">Hello list,</FONT><FONT face=Geneva color=#000000 size=2 FAMILY="SANSSERIF"><BR></FONT><FONT face=Arial color=#000000 size=2 FAMILY="SANSSERIF">I have been trying to modify three legs for new casters. It required that I cut the legs short by 1.2 inch to maintain hight(done). In addition it requires that I enlarge the existing  .86 inch hole to 2 1/8 inch at .25 inch deep.</FONT><FONT face=Geneva color=#000000 size=2 FAMILY="SANSSERIF"><BR></FONT><FONT face=Arial color=#000000 size=2 FAMILY="SANSSERIF">In addition the existing .86 hole needs to be deeper by 1.5+ inch but it is oversize by about .085 inch.</FONT><FONT face=Geneva color=#000000 size=2 FAMILY="SANSSERIF"><BR></FONT><FONT face=Arial color=#000000 size=2 FAMILY="SANSSERIF">I have tried using my drill press and a forstner bit for the large shallow hole but could find no way to secure the leg enought to get it started.</FONT><FONT face=Geneva color=#000000 size=2 FAMILY="SANSSERIF"><BR><BR></BLOCKQUOTE></FONT><FONT face=Geneva color=#000000 size=2 FAMILY="SANSSERIF"><BR><BR>Gene;<BR>Try plugging the hole flush with the old surface....then you will be able to hand drill appropiate sized holes without bit wandering....worked for me.<BR>Jim Bryant (FL)</FONT><FONT face=Geneva color=#000000 size=2 FAMILY="SANSSERIF"></FONT><BR><BR><BR>**************<BR>Looking for a car that's sporty, fun and fits in your budget? Read reviews on AOL Autos.<BR>(http://autos.aol.com/cars-Volkswagen-Jetta-2009/expert-review?ncid=aolaut00030000000007 ) </FONT></BLOCKQUOTE></BODY></HTML>