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Re: Press Fit
A slightly undersized reamer is definitely the way to go. We've done all kinds of things in the past, but if you want a hole precise to .0001", use a good reamer.
We machined bearing blocks this year on our CNC mill, and some turned out as slip fits, some were press fits. Keep in mind this is the same end mill, same program, same bar of stock. You would think they all come out the same, but there is never a guarantee. Between a bit of high grit (400 or so) sand paper and snap rings, things were easily "good enough" for FRC. But...
Ideally, I would drill it undersize for the reamer and then ream it slightly undersize. Picking the size reamer you want is the hard part, but I would think .0005" under or so would be good enough. Other methods may work, but a reamer is going to give you the closest thing to a true cylinder that you can get.
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