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The bushes for this rack are still available, but need to be imported from Holland. So the decision was made to turn a set up. This posed a small problem that we don't have any decent materials suppliers around here, so where to get the required nylon? The answer came from a local general hardware store - 10mm thick nylon kitchen chopping boards.
The bush dimensions are 23.2mm outside diameter, 17.75mm internal diameter and 14mm overall length. Using 10mm thick material therefore required making four bushes, two for each end, with one 10mm and one 4mm.
First they were cut out very roughly using an electric jigsaw.
The four blanks were then centre drilled at 6mm, fitted with a bolt as an arbor, and mounted in my trusty model lathe. Turning plastic like this is nice because you can take fast, deep, cuts with an acceptable finish. Even on a model / watchmakers lathe taking 2mm a pass isn't a problem, so the bushes shape up nice and quickly!
Once the outers are sized, time to remount and work on the bores. For these, I drilled to 12mm and then turned out using a hand graver to size. This allows better control, especially with a soft material, and makes it easier to ensure the hole is centred properly - important because there will be two bushes at each end. If they don't line up properly then only one will be doing any work! Once finished, the bushes can be fitted to the rack cage.
