1" OD 1/2"" ID the first reamer after drilling the 4130 out might be under sized, the 2nd reamer I used, the boring bar slid in snugly. Slitting saws are awesome, zip, zip, and done. The setup took longer.
I think your right, without the countersink in the opening there was an effort to get the bar lined up to pass into the bushing. Prior to the slits, the bar pulled suction with my finger on the end pulling it out.
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