...any chance that 1/4" spacers could be used under the flange?
It does affect the headroom/tool height above the fixture, but could do in a pinch.
Brino, I wish you would have posted that before I cut them off, that would have been a better solution and would have allowed more guide length. I didn't think of that one.
Here is what I did
First I built an expanding arbor to hold the bushing
Tapping the end with a 1/8 pipe tap
Cutting the expansion slots on the band saw
I couldn't find a 1/8 socket head pipe plug in my stash, to I grabbed the nearest 1/2 inch bolt and made one. I tapered the end a bit at about pipe thread taper, then threaded it with a 1/8 pipe die
The completed ''pipe plug'' The crud in the threads is never seize, I didn't want any galling.
I scribed a line in the lathe with a carbide bit just to give me a reference for the next operation.
With the drill rotating I was able to make a nice cut with the cutoff wheel. Sorry there is no pictures of sparks flying, that takes two hands to hold the drill.
I move over to the other side of the grinder just to knock off the sharp edges and clean things up a bit. I discovered that I had really good control of the part, so I just used this method to finish grind to length. Grind a bit, then measure, rinse/repeat.
A quick deburr in the ID
And the final product. These are +/- 0.002 on the length, well within tolerance.