I realize it would take the fun out of it, but couldn't ya buy one?

He could if it wasn't some odd size he needed. He needs it to be the same interior dimension, but wider. (taller?) It'll take more time researching it to find one that will work then it will to make one.
It seems he'll be able to use the hole saw to get it close, so it shouldn't be as bad as he was thinking.
He's setting up the mill as we type. Guess I better get the camera again.