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What is the easiest/most consistent way to cut bushings? I absolutely butchered mine yesterday.
Well it may not be the easiest way. But I always had success with a razorblade. I put the bushing on a baseplate with kingpin and then cut the bushing carefully. I put a washer right there, where I want to cut the bushing and stay in that line. It takes a while but it always worked really well. I hope that made sense.
I had never thought to use a washer as a guide but definitely keeping it on the kingpin and cutting a little, then turn the bushing and cutting a little more, round then if it hasn't cut right through, take it off and gently peel the side a little and cut the middle remainder.
Often trying to cut through, the blade would always go on a bit of an angle so I would end up with a lop sided bushing. Even then, using griptape - sheet stuck to a wall or just on your board - to finish it nicely is good if you do muck it up a bit.
A serrated edge kitchen knife seemed to work well, almost a steak knife, but with smaller teeth, so not quite so rough in the cuts and it got through pretty well.
If it is only a mm or so, just sanding it off works better though, but 2 mm or more, cutting it seems to be the winner.
Edit: Should have posted this too, from a while ago now, but it still works.