Best way to adjust dowel fit in oak?

[alanambrose]

Hi,

I have a design for some coat hooks I want to use in a few places around the house. This uses some rough green oak for the 'base' and 30mm bought-in machined dowels for the 'pegs'. I'm not much of a woodworker :) but I did a rough little prototype to check the design and figure out a fixture to drill the 30mm holes at a 30 degree angle on a drill press:



(Please ignore the peg at 90 degrees - that was only done to check the dowel fit.) I was pleased to find that the 30mm Forstner bit I used gave a clean entry cut even being used at a 30 degree angle. The problem was that the '30mm' dowels are slightly bigger that the '30mm' Forstner bit I used. The discrepancy is about 0.3mm with the dowel being ~0.2mm too big and the holes ~0.1mm too small. I would be happy making the holes 0.5mm bigger than the dowels giving an easy fit and room for some glue.

The question is how? I don't have a lathe and anyway this would be tricky because of the 30 degree angle. Some kind of adjustable bit would work. Or I could buy a bunch of different bits to find one that cuts oversize - but I would need a bit that was happy with an entry angle of 30 degrees without tearing out the side of the hole. In one example I want to put about 30 'hooks' in a line so manual adjustment with a sander isn't looking a great way to go (and the dowels are quite hard anyway.) A trimming router and an oval template - I could cnc machine that in aluminium I guess? Any other ideas? (And yes, I know my mitre saw blade is blunt :) )

Ta, Alan