pic: Cheap 6WD

[Ivan Helmrich]

One way to keep holes through the wood from deforming is to soak the interior of the hole with thin CA (Cyano Acrylate) adhesive. It will wick into the surrounding fibers and make the area very hard and distributes the stresses to a larger area. I've done this for 1/4" dia. holes with good success, I wouldn't hesitate to do this with a larger hole though.

This also works well for holes that are threaded into wood. Drill the hole, form the thread and saturate with CA. Let the adhesive cure fully and re-tap the hole. This is especially helpful where the hole is in the edge of plywood as it helps bond the plies together.

The CA makes some nasty fumes so do this with ventilation and don't soak too large an area at one time, it's exothermic. You will already have your safety glasses on, slip on some rubber gloves as well. It's easy to glue yourself to the part you are working on.