Recently I needed to shorten the bushing portion of my 3/4″ O.D. brass router template guide so I could use it with a thin template. Here’s how I accomplished the task without a hacksaw: I drilled a 3/4″-dia. hole through a piece of scrap that was slightly thinner than the template I planned to use. Then I inserted the bushing in the hole and held the scrap and template guide against a belt sander. Applying light hand pressure with the sander running, I was able to quickly grind the soft brass down until the bushing was flush with the scrap.
-Jim Moorehead
Barrigada, Guam
