The first pic is the UND all cured and the next step is to use the forms to drill out the tube holes.

First step is to drill out a clearance area of about 3/8″ in the center of the holes. All thats needed is room to get the drill guide rod through so that it can center. As long as there is clearance to get the rod at the correct angle between the hole centers any size hole is OK as long as its smaller than the final hole that we want.

The pics show that I have clamped a bit of wood to the exit side of the hole so that when I drill through it get gets a nice crisp edge.

The last pic shows a tight template hole for the drill guide. This hole is positioned in the center of the hole jig, it works out about 5mm from each edge. What this results in is the tube holes being bored at a correct angle through the gear leg tabs. It is NOT a nice square 90 degrees to the round hole. It is in fact a hole drilled an an angle through the tab.

It might sound confusing but if you are going to do this job, if you begin to set up up and then look at the pics it will all make sense. Remember this is my third go at it and now I have an idea of how it can be done. I became smarter very very slowly.

Cured UND

Hole drilling

Lining it up