Good to know. Does that mean I can also turn it down to fit a 1/2 chuck in the tail stock (or should I find a larger chuck instead? )?You might want to use a .625" reamer. Until a new reamer is broken in, it will ream about a half thousandth oversize. I think you'll find the motor shaft is usually at .6245" diameter most of the time.
BTW- the shank on a reamer is usually soft enough to take a hacksaw and cut it off to the length you need. I've done this many times over the years when I needed a shorter reamer.
Ken
6061 aluminum.What material are you making the part from?
Would a shop made "D" reamer work?
David Gingery explains in one of his books how to make them with hand tools if I remember right. I'm not a skilled machinist but I have more skills now than I did when I made the first one. It was merely a shaft of the desired diameter with the end sliced off at an angle. It worked well for aluminium one time use. That method is less sophisticated than one I saw in a thread on this site when I googled "D" reamer a moment ago.Huh. That''s a pretty cool idea, but I think making one is a little beyond my skills at this point.