Odd sized reamer required for rudder/brake pedals???

[birdus]

So I did my first welding job—rudder pedals and brake pedals for my Super Baby Great Lakes. Turned our pretty good.

Then, yesterday, a nice new 3/4" reamer came in the mail from Grizzly. I reamed out the 7/8" tube of the brake pedals and slid them right onto the rudder pedals. Perfect fit. NOT! Turns out the 3/4" tube of the rudder pedal is .753". That is clearly greater than the dimension to which the reamer reamed out the brake pedals. How do I know this? Because I ruined one brake pedal trying to make it fit (it rattles around now), and the other brake pedal and the rudder pedal and a third piece of tubing are almost unbelievable stuck together. Seriously. Shockingly stuck. The garage has been completely destroyed by F-bombs.

I'm ready to throw the stuck rudder pedal and brake pedal in the garbage (heat doesn't help), and I'm going to have to cut the tube off the other brake pedal and weld a new one on.

Now to my question: once I've fixed or rebuilt the components that I've either ruined or gotten impossibly stuck, how the hell do I ream out the brake pedals to make them fit the rudder pedals? Not really interested in spending a couple hundred bucks for an adjustable reamer if I can avoid it.

What a disappointment this has turned out to be.

Thanks,
Jay

 

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