this was exactly what i had in mind when i did mine, so congrats on doing what seems to be such a perfect job. i have now changed my mind and plan to put the sleeve all the way through, but i am still curious as to how you got such a great fit. mine were pathetic.

 

google 'annular cutter'

A hole saw is basically a cheap knockoff of this tool, and all your walking and hole roundness issues will go away if you get a proper one.

 

right tool for the job. but i doubt most are going to spend $100+ for the bit for a single use job.

of course it doesn't have to be perfect once you epoxy it in place.

 

Friend of mine helped me out.actually he did all the work lol.he has a jig set up for his drill press.once the holes were made he pressed in the tubes.

 

What size annular cutter did you use? Is your I.D. 1"?

 

which epoxy do you speak of, i thought you had to weld them...

 

Devcon aluminum putty

 

This is how I did mine.


http://www.rotaryeng.net/Welded-steel-p-port.html

 

would like too know this

 

I hope to put this info to good use next year.