Router guide bushing is too long...

Mike, I’ve sanded off guide bushings before, didn’t hurt a thing. I just used a metal cutting file, and made a few quick swipes and it was short enough for the jig I was using.

Mark

-- Mark DeCou - American Contemporary Craft Artisan - www.decoustudio.com

Thanks Mark. I will give the file a try first.

-- Mike P., Arkansas, http://mpounders1.blogspot.com

I just used a hand hacksaw, and then sanded it smooth. It works fine.

Brass is real tough filing.

-- -** You are never to old to set another goal or to dream a new dream ****************** Dick, & Barb Cain, Hibbing, MN. http://www.woodcarvingillustrated.com/gallery/member.php?uid=3627&protype=1

I have done this before
I used a die grinder , fine cut file ,and sand paper to smooth it.

-- E J ------- Always Keep a Firm Grip on Your Tool

And even if you don’t get it perfectly flat it is no big deal as your only useing the sides of the bushing anyway, just need to get it shorter than the template.
Also check out this link for some tweaks to help make adjusting that dovetail jig a little bit easier. The jig is from HF as well.
http://lumberjocks.com/projects/42759

Thanks for all the input and especially for some tips on tweaking the jig also….you have probably increased my chances of success!

-- Mike P., Arkansas, http://mpounders1.blogspot.com

Mike, Could you make an auxilary base plate for your router that is thicker? This way you can keep the guide bushing in tact in case you need to use it as is in the future.

-- Pops ~ In So Cal...