<!doctype html public "-//W3C//DTD W3 HTML//EN"> <html><head><style type="text/css"></style><title>Re: modify legs for new casters</title></head><body> <div>Hello Gene,</div> <div><br></div> <div>The problem you describe is common when fitting improved castors with a long narrow spigot (which needs to be a moderately firm sliding fit in the hole to provide adequate radial support).</div> <div><br></div> <div>Since the central spigot hole needs to be reduced in diameter, if you plug it first, the plug will provide support material for locating the Forstner bit while drilling the 2 1/8" recess for the flange. You can drill the spigot hole after the flange recess is drilled. I use a Portaline drilling jig, which is a US tool, for drilling the spigot hole on axis with the leg. Its important that the spigot hole is vertically aligned with the leg or the castor will tend to self steer when moving the piano around (in a similar fashion to a damaged supermarket trolly). My Portaline jig has two holes in the base flange which enables the jig to be screwed to the bottom face of the leg prior to drilling the spigot hole. The screw mounting holes can be plugged with hammer shank after the spigot hole is drilled (should you wish to conceal the evidence).</div> <div><br></div> <div>Regards,</div> <div>Ron O.</div> <div><br></div> <blockquote type="cite" cite><font face="Arial" size="-1">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></blockquote> <blockquote type="cite" cite><font face="Arial" size="-1">In addition the existing .86 hole needs to be deeper by 1.5+ inch but it is oversize by about .085 inch.</font></blockquote> <blockquote type="cite" cite><font face="Arial" size="-1">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></blockquote> <blockquote type="cite" cite><font face="Arial" size="-1">I did attach 1/8 birch plywood to the surfact to locate the center and attempt to get the big bit started but the ply keeps splitting.</font></blockquote> <blockquote type="cite" cite><font face="Arial" size="-1">Possibly my new bit from Harbor Freight needs to be better quality?</font></blockquote> <blockquote type="cite" cite><font face="Arial" size="-1">Any ideas would be helpful.</font></blockquote> <blockquote type="cite" cite><font face="Arial" size="-1">Gene</font></blockquote> <div><br></div> <div><font face="Arial" size="-1"><br></font></div> <x-sigsep><pre>-- </pre></x-sigsep> <div><font face="Times New Roman" size="+1" color="#0000FF"><b>OVERS PIANOS - SYDNEY</b></font></div> <div><font color="#000000"><i>   </i></font><font color="#0000FF"><i>Grand Piano Manufacturers</i></font><font color="#000000"><br> _______________________</font></div> <div><font size="-2" color="#000000"><br> </font><font color="#000000">Web http://overspianos.com.au</font></div> <div><font color="#000000">mailto:ron@overspianos.com.au<br> _______________________</font></div> </body> </html>