"RST Engineering" wrote in
:

Orval, I ain't a tinbender and don't pretend that I am. However, if
the (for instance) 1/4" hole is a sixty-fourth undersize, it should
come out 0.234". A letter-D drill will take it out to 0.246"
(admittedly with some triangularity) which should significantly cut
into the laser hardened part of the steel, then the reamer only has to
take off the last four thou.

If you want to cut yourself some more leeway, a letter-C drill will
take it out to 0.242 and then you get to ream eight thou.

OK. I did try to file out most of it. My drill supply wouldn't be all that
large and there aren't a lot of places wit a good suply handt to where I
live, but I will try that.

I did try and sharpen the one I have, but it didn't really work. Used a
little slip stone I have for gouges and it was OK for getting the burrs
off, but not so great for sharpening.
I think the quality of the reamer is probably the biggest prob I had.
Anyway, we worked through a few more holes today using the worn one to at
least get some of the harder stuff off and now it'll be relatively easy to
do those holes over when I get a new reamer.