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Drill Bushings 3 Types

We design, manufacture and market Special Aircraft Tools.  Our most popular items are our Drill Bushing Sets.

We manufacture different types of drill bushings – 3 types. All bushings are machined to a tolerance of ± 0.001”, from O-1 Tool Steel. They are then heat treated and tempered. The respective bushing size is laser engraved on the head of the bushing.  A tray is supplied with each set. The tray is machined from 6061-T6 aluminum and anodized a red color. The bushing sizes is engraved on the tray adjacent to the respective bushing location.

Our Most Popular Set

Firstly, our most popular set is the 27 Piece OD Drill Bushing Set (Transfer Bushing).  The outside diameter of these bushings has been chosen to accommodate fastener holes for standard, oversize and under sized aircraft fasteners. We also produce an 8 Piece OD Drill Bushing Set (Transfer Bushing) to accommodate just the standard size aircraft fasteners.

27 Piece Set Top View
27 Piece Set Top View

Interfaces with Drill Bushing Block

The second of the 3 types, we produce a 16 Piece ID Drill Bushing Set (Slip Fit).  The bushings are machined to a OD of 0.500”.  The ID (pilot hole) through the bushing varies.  The pilot bores size of each bushing has been selected and machined to guide drills to produce standard, oversize and undersized aircraft fastener holes. We also produce a 5 Piece ID Drill Bushing Set (Slip Fit) for just the standard aircraft fastener holes.  The Drill Bushings of this type have been designed to interface with our Drill Bushing Block.

Slip Fit ID Drill Bushing 16 Piece Set
Slip Fit ID Drill Bushing 16 Piece Set

Interfaces with Drill Egg Cup

Lastly, we produce a 16 Piece ID Threaded Drill Bushing Set. The ID sizes are identical to the “Slip Fit” bushings noted in item 2 above.  However, the OD of these bushings is a ½” 13 TPI NC thread.  These bushings have been designed to interface to our Threaded Drill Egg Cup.  Again, we can supply this bushing in a set of 5 Pieces for the standard fastener sizes.

 16 Piece Threaded Drill Bushing Set with Tray
9536797-016 16 Piece Threaded Drill Bushing Set with Tray

We can also sell bushings individually to replace missing or lost bushings.

Finally, we have started a production run to produce larger Transfer Bushings. A 6-Piece set with outside diameters up to 0.7500” .  Also include is a 0.7850” diameter transfer bushing. This size is purpose designed and intended to be used during the installation of Brownline seat/cargo track.  These will be available in early February 2020.

For more detailed information visit our ON-LINE STORE at:

METRIC Drill BushingS

Metric Drill Bushings. We have had a few inquiries, from potential end users, about the possibility of manufacturing metric drill bushings.

Manufacturing different sizes of bushings, like bushings turned to a specific metric size, is not a difficult task. Modern CNC machines easily convert from one measuring system to the next. This is accomplished with with a simple coding change.

Therefore, the decision to manufacture bushings is solely based on the demand. In some cases, we will evaluate a request on the perceived demand for the finished product.

As well, we have also had a request for a conversion table.

Use the chart below to easily convert to the metric equivalent. The table shows the finished machined Outside Diameter (OD) of our 27 Piece Set of Transfer Bushings (Part Number 9536797-027). The far right column shows the metric equivalent.

Metric Conversion Chart

Conversion calculation is based on 1 inch = 25.4 mm

In conclusion, if you would like SAS-Canada to consider machining Drill Bushings to specific metric sizes, please contact us . Indicate your specific sizes and a list of dimensions to satisfy your specific requirements for a metric set .

To find out more about the complete line of our Special Aircraft Tools, go to our On Line Store at:


Machining Ideas into Finished Parts

Brownline TrackS

Brownline Seat/Cargo Track – Drill Bushing

We receive request from customers frequently. One such request came in a few weeks ago.  A customer wanted a drill bushing he could used as a guide for drilling Brownline Seat/Cargo Tracks.

We have been manufacturing Special Aircraft Tools for almost 20 years.  From time to time, we receive inquiries if we have made or would consider making “specific purpose” tool.  What customers want and what specific application could be made easier or more accurate with a “Special Tool” is always of interest. Improving quality is always top of mind.

Brownline and most other manufacturers of seat/cargo tracks manufacture the tracks to Military Specification MS33601.

Solving a Customer Problem

The problem is to drill a pilot hole in the seat/cargo track extrusion base, concentric with the 1.0” spaced holes machined in the top of the track extrusion.

As it turns out, like most jobs, this task can be simplified by employing a drill guide.  So, to solve this problem we propose a “Drill Bushing” with an Outside Diameter to fit in the machined hole.  The Inside Diameter is 0.1285” (to accommodate a # 30 Drill) .

Specific Purpose – Specific Solution

Brownline Seat/Cargo Track Drill Bushing

This drill guide, when used, will ensure the resulting 0.1285” pilot hole in the extrusion base will be concentric with the machined holes in the top of the seat/cargo track. 

With the initial pilot hole drilled, the next step is to properly size and countersink the fastener hole to the installation specifications.

Typical Brownline Seat/Cargo Track with Drill Bushing in Place.
Typical Seat/Cargo Track with Drill Bushing in Place

Seat/cargo track drill bushings , is machined from O-1 tool steel. Each bushing is heat treated, tempered and engraved on the head. Machining of the these drill bushings is within a tolerance of ± 0.001″.

Machining Ideas into Finished Parts

In conclusion, we propose to machine a test production run to determine if there is an adequate demand for this tool.  Interested in adding a Special Tool to your tool box? Please let us know . We would appreciate your comments and feedback.

To access our online store

Drill Squares – 3 Sizes

Choose the Drill Square size that’s right for your application.

Special Air Services-Canada Inc. has been manufacturing Special Tools for the Aircraft Industries for more than 20 years. During this time, we have accepted customer suggestions and requests for tool designs and custom sizes. So, when designing and manufacturing these Drill Square, its only logical to manufacture and market what customers need and will choose to buy.

Here are a few photos of the three sizes of Drill Squares we produce.

Choose the Size for you Application
Choose the Size for you Application

We now Offer Drill Squares in 3 Sizes

Drill Square P/N 9536814-201
Drill Square P/N 9536814-201 (Dimension (2.0″ X 1.5″)
Drill Square P/N 95326814-301
Drill Square P/N 9536814-301 (Dimension 1.5″ X 1.5″)
Drill Square 9536814-401
Drill Square P/N 9536814-401 (Dimension 1.5″ X 1.0″)
  1. Drill Square P/N 9536814-201 (Dimension 2.0″ X 1.5″)
  2. Drill Square P/N 9536814-301 (Dimension 1.5″ X 1.5″)
  3. Drill Square P/N 9536814-401 (Dimension 1.5″ X 1.0″)

Heat treated tempered and polished

We machine each Drill Square from 1/2″ thick O-1 Tool Steel. Then we heat treated and temped each Drill Square . The heat treating and tempering produces a very hard and scratch resistant tool. Typical hardness is about 59 on the Rockwell C Scale. Each Drill Square then polished.

Drill Square Selection

Firstly, Drill Square P/N 9536814-201 is the most common and typical choice for most customers. It offers the longest length on the 2.0″ leg to provide the maximum guiding surface when drilling. It works best with diameters larger than #10 Drill size having a flute length of over 2 inches. The longer length offers better accuracy. Furthermore, the shorter leg (1.5″) works well with a smaller drill like a #30 or #40 drill. We call this one the Standard Drill Square.

Secondly, to satisfy a request from a Maintenance Repair Overhaul (MRO) operation, we designed Drill Square P/N 9536814-301. They wanted a shorter guide leg to work with smaller diameter drills like a #30 or #40 Drill. These drill sizes typically have a flute length less than 2 inches. This MRO purchased enough Drill Square to provide a Drill Square to each employee working in their Structures/Sheet Metal facility. We call this one the Medium Drill Square because of its compromised leg lengths.

Lastly, based on our own experience, we designed Drill Square P/N 9536814-401. We wanted a Drill Square to use in tight spaces. It was designed in an effort to accommodate the shorter flute lengths of stub drills, usually chucked in an angle drill. We call this one the Stubby Drill Square because of its compact design.

Drill Squares – 3 Sizes Another Lifetime Tool

Like all the tools Special Air Services-Canada Inc. manufactures, we select materials and produce designs that are functional , resist wear and abuse. Craftsman who originally chose our tools almost 20 years ago still used them today. If you see any of our tools in a professional’s tool box, ask him what he thinks of the quality and functionality of our product. In short, we are sure you will only hear good things. If on the rare chance someone has a suggestion or says “I wish SAS Canada would have made it differently”; have them contact us. Above all, as the end user, we truly value their opinion.

To learn more about the Drill Squares and the other tools we manufacture follow the link below:

Machining Ideas Into Finished Parts

Transferring Fastener Holes

The Task: Transferring Fastener Holes

So, you have been assigned the task of Transferring Fastener Holes from an old or damaged sheet metal part to a new replacement component. To be accurate, you need to ensure the hole on the new parts are concentric and precisely located with the fastener holes in the older component.

For some technicians, simply using the old component as a drill guide seems adequate. For some application this may be acceptable.  However fastener holes in the old component, may be oversize or elongated .

Therefore, you may unintentionally copy the inaccuracy to the new component.

The Solution:

However, if you want to maintain accuracy us these “Transfer Drill Bushing“. This will ensure the new fastener hole is accurately located and concentric with the desired fastener hole location. 

We specifically designed our 27 Piece OD Drill Bushing Set to assure the accurate transfer of holes.

Transfer Fastener Holes  - 27 Piece ID Drill Bushing Set
27 Piece ID Drill Bushing Set

27 Piece OD Drill Bushing Set

Subsequently, the location of the fastener hole is transferred using this drill bushing as an aid . The bore of the Drill Bushing accurately and concentrically guides a “pilot” drill through the new component.

Transferring Fastener Holes

We have designed the OD (Outside Diameter) of each Drill Bushing to accommodate fastener diameters used in the aircraft industry. The Drill Bushings in this set fit standard, oversize and under-size fastener holes.

Drill Bushing with an OD of 0.1875″ or less, have a bore machined for a #40 pilot drill size.

Drill Bushings with an OD greater than 0.1875″, have a machined bore for a #30 pilot drill size.

Now the Pilot Hole is Drilled:

With the pilot hole accurately located and drilled in the new component, it is time for the next step.

The next step uses standard drills, step drills or even reamers to finished the fastener hole diameter.

The application’s specification may even require a combination of hole-making tools.

In conclusion, the OD Drill Bushing Set is the ideal tool to use to Transfer Fastener Holes.

To learn more or to order tools on-line, follow the link below:

Hand Drilling Tool System SAS-Canada

By Far The Easiest, Best and Most Accurate Hand Drilling Tool System For Making Fastener Hole.

Customer Ideas – Key to our success

Special Air Services-Canada Inc. designs and manufacturer Special Aircraft Sheet Metal Tools, as part of a Tool System, for the Aircraft Maintenance and Repair Overhaul Industry (MRO).  We have manufacturing these tools for over two decades.   We incorporate new and improved design features  with each new release.
These changes result from our own experience and those of our colleges.  Above all, in many cases,  the change are triggered by customers request for improvements.  We listen to our customers.  When they express an idea for a change, it is quickly evaluated.  If the change is cost effective and beneficial to the end user, it is likely included into our next production run.  As the result,  we have developed our current and superior Hand Drilling Tool System.

Aircraft Sheet Metal – 
Hand Drilling Tool System

As a result of constant effort and attention to customer requests, we have developed a Hand Drilling Tool System.  Furthermore, its only logical to make sure each component is designed to interface with other tools in the system.  As an example, all the Slip Fit ID Drill Bushings mate seamlessly with the Drill Blocks, Drill Cups, and the soon to be released, Drill Stand.

Some of the Special Aircraft Sheet Metal Tools are shown in the Photo Gallery above.  Finally, to learn more and see all the tools we manufacture and market use the link to go directly to the SAS-Canada ONLINE STORE:

“Machining Ideas Into Finished Parts”

16 Piece Slip Fit ID Drill Bushing Set

2018-10-27 – Now Available

For a number of months, we have been offering our 5 Piece Slip Fit ID Drill Bushing Sets (Internal Diameter).  So, based on requests for more choices, from our customers, we have  manufactured a 16 Piece Slip Fit  ID Drill Bushing Set.

A need for more sizes

In the past we had manufactured the 5 fractional sizes as our 5 Piece  slip Fit ID Drill Bushings.  These are in stock and available from our online store:

Our custom have expressed a need for even more sizes and suggested internal diameters to accommodate specific fractional, numbered and lettered drill sizes used to drill faster holes in the aerospace industry.  The requests have come from individual technicians and also from Maintenance Repair and Overhaul facilities.

Finally, after determining the corresponding preferred drill sizes, we came up with a set of the most common and most requested drill bushings.  Select the link below  for a PDF listing of the resulting sizes .

16 ID Drill Bushing Size

We have now completed a production run for the total preferred Sixteen  sizes.

New Tray Design

First of all, we designed a new tray to accept the 16 ID Drill Bushings,  the most requested sizes .  As you can see (in the photos below) the new tray is similar to the tray supplied with our 27 Piece OD Drill Bushing Sets, offered for the last few months.   We have chosen “Red” as the anodized color to make the tray highly visible in you tool box or while working near aircraft and components.

Hence the new design produces a practical compact tray.  The respective bushing ID size is engraved below each bushing receptacle .  Making it easy to return bushings after use. Therefore, this feature assists in tool a management systems.

Same Quality – 16 Piece ID Drill Bushing Set

Above all, we strive to maintain the highest quality.  Our 16 Piece ID Drill Bushing Set is machined from Precision Ground O-1 Tool Steel sourced from a Pennsylvanian USA supplier .   Furthermore, we maintain a  tolerance of ±0.001” .  After turning, we heat treated and tempered the bushings.  This produces a hardness of 60+ on the Rockwell “C” scale.  The ID size in decimal notation, as well as fractional, number or letter notation, as applicable; is laser engraved on the bushing head .

Visit our online store to see more information

“Machining Ideas into Finished Parts”

Aircraft Cable Swager Machine Kit

Aircraft Cable Swager Machine Kit

Aircraft Cable Swager Machine Kit

Locoloc® M2-K – Type II – Kit

Serial Number: 2240

Manufactured by Loos & CO,  USA

We are offering the above Aircraft Cable Swager Machine Kit, a  well maintained in excellent used condition , for sale.

The first three images  below have been downloaded from the Loos & Co website.  They depict the currently available kit.

M2 Aircraft Cable Swager Machine Kit
Loos & CO Current M2 Cable Swaging Machine


The Aircraft Cable Swager Machine Kit  is a more sophisticated swaging machine. It is bench mounted, hand powered with crank geared down for easy operation. This swaging machine will accomplish the swaging of AN or MS type fittings on all galvanized and stainless steel cable up to and including 3/8″ diameter.

M2-K Kit Showing Components Aircraft Cable Swager Machine Kit
M2-K Kit Showing Components

Dies contained in the Aircraft Cable Swager Machine Kit
Dies contained in the Kit

The image above shows the components included in the M2-K Kit.

  • The kit conforms to MIL Spec MIL-S-6180
  • M2-K Shipping Weight: 425 Lbs.
  • Straight Shank Dies Weight: 8.5 Lbs. ea Set
  • Ball Terminal Dies Weight: 10 Lbs. ea Set

The images below show the actual swaging machine which is for sale including all of the item shown in the images above.

This is a Recent Photo of the Aircraft Cable Swager Machine Kit
1. Recent Photo of the Aircraft Cable Swaging Machine Kit Which is Being Offered for Sale

This is a Recent Photo of the Aircraft Cable Swager Machine Kit
2. Recent Photo of the Aircraft Cable Swaging Machine Kit Which is Being Offered for Sale

This is the Last of Recent Set of Photos of the Aircraft Cable Swager Machine Kit
3. Last of Recent Set of Photos of the Aircraft Cable Swaging Machine Kit Which is Being Offered for Sale

We primarily used this machine to assemble aircraft control cables

This lightly used swagging machine has served us well over the years.  We have scrupulously maintained it during that time.  The machine is currently in storage.  Although there is some dust accumulated on the surfaces, there is no corrosion evident or visible.

When the City of Edmonton closed the downtown airport about 5 years ago we were forced to move to a smaller shop.  The unit was placed in storage at our new smaller location, but due to space restriction, we never set it up after the move.  We have now decided to sell the complete kit.

Also available is about 250 individual MS and AN aircraft cable terminal ends which are in our current inventory; a $1,000.00 plus value.

Also used for Marine Cables

Over the years we also assembled many marine, sailboat cables.  Most of the cables terminal ends used in the rigging on sailboats can be readily swaged with this machine.

The weight of the complete kit is about 425 lbs, so truck transport or local pick-up are the only freight options.

If you would like more information or more detailed photos please contact us at:

OD Drill Bushings – Now Laser Engraved

Laser Engraving the OD Drill Bushings

As we have stated in the past, we are attempting to provide useful, durable and professional tools for the Aviation Industry.  These tools are also used by professionals who take pride in their precise work.  OD Drill Bushings Now Laser Engraved.

Improvements with each production run.

Sample of Laser Engraved OD Drill Bushing OD Drill Bushings Now Laser Engraved
Sample of Laser Engraved OD Drill Bushing Head

We have been manufacturing drill bushings and other drilling aids for over a decade.  With each new production run we attempt to improve on the previous release of a particular tool.  Therefore, to meet this goal, we have improved the “Tried and TrueSAS-Canada Outside Diameter Drill Bushing design.  Since the initial release we have employed  our CNC milling machine to mechanically engraved the  outside diameter on the head of the bushing.    On the current release of drill bushing a laser engraver is used to apply the  diameter and other text .

No Big Deal you say…

OD Drill Bushing 27 Piece Set Kit OD Drill Bushings Now Laser Engraved
27 Piece OD Drill Bushing Set

Drill Bushing 8 Piece Set Kit OD Drill Bushings Now Laser Engraved
8 Piece Drill Bushing Set (Standard Fastener sizes

Maybe, but none the less it is an improvement in manufacturing process and the resulting consistency and quality.  Functionally the engraving remains almost the same. However  the application of the laser engraved text, presents a crisp, more legible and consistent professional appearance.  This change is just another small design improvement to ensure our line of tools perform better, last longer and stand out in your tool box.

Sold as Individual Bushings or Sets.

We offer Standard OD Drill Bushings in sets of 8 or 27 pieces, as shown above.  Rather than maintaining stock our Ultimate Set of 39 bushings is manufactured and assemble on a made to order basis.  OD Drill Bushings Now Laser Engraved.  We also sell individual bushing to replace missing or damaged bushing from previously purchased drill bushing sets.

Custom Orders Possible

In addition, we manufacture special order custom bushings, in varying lengths, head size and diameter.  Send us your requirements and we will provide an estimate and a CAD drawing of the custom part.

More detailed information

For more detailed information follow this link to our online store

Machining Ideas Into Finished Parts

5 Piece Set – ID Drill Bushings – In Stock NOW!

In stock at last.  

We are pleased to announce we have now completed a production run of a newly designed Drill Bushing.  We call it an ID Drill Bushing.  some technicians refer to this bushing type as a “Slip Fit” drill bushing.  At first glance it appears to be a standard “slip fit” drill bushing.

ID Drill Bushing Note: Set Screw Receptacle
ID Drill Bushing Note: Set Screw Receptacle

ID Drill Bushing. Note: Size of ID Bore Engraved on Head
ID Drill Bushing. Note: Size of ID Bore Engraved on Head

Subtle Design Improvement

We have, however, improved the design by incorporating a machined receptacle into the outside diameter of the  Drill Bushing.  The receptacle is positioned to mate precisely with the ” half dog” of the set screw.  Together, the set screw within the receptacle work to securely retain the drill bushing in the SAS-Canada Drill Bushing Block or the SAS-Canada Drill Bushing Cup during use.

ID Drill Bushing.
ID Drill Bushing. Showing Stainless Steel Set Screw in Drill Block and Mating Receptacle in ID Drill Bushing

Initial Offering.

The initial offering of these  Drill Bushing is in a 5 Piece set plus a 6061-T6 Aluminum Tray.  The tray is now anodized to ensure corrosion and scratch resistance and to extend its service life.

5 Piece Set - ID Drill Bushings.
5 Piece Set – ID Drill Bushings. ID Bore Sizes to Accept the Following Drill Sizes: #40, #30, #21, #10 and 1/4″. Also Shown the SAS-Canada Drill Bushing Block with Set Screws.

5 Piece Set - ID Drill Bushings.

5 Piece Set – ID Drill Bushings. ID Bore Sizes to Accept the Following Drill Sizes: #40, #30, #21, #10 and 1/4″. Also Shown the SAS-Canada Drill Bushing Cup with Set Screw.

Complete Tooling System.

At Special Air Services-Canada Inc. our commitment is to design and produce a fully integrated and comprehensive tooling system.  We are working to meet the demands of the Aviation/Aerospace Industry.  Our goal is to offer tools that work together,  precisely and effectively to help our customers become more capable technicians.

To learn more, select the link

Machining Ideas Into Finished Parts