FT detachable base construction/installation

Made my first tubular brass base for FT 
(SemFed BB from Brigade.... love that model 
Tony!). 

Problems: 
1) Squaring a hole in the bottom of the BB - 
most files wouldn't work (not enough travel) 
and the dremel likes to make rounded corners. 
Suggestions? One idea is filling excess 
(assuming round-ish hole) with Plastic Metal or 
some such compound for filler. 

2) Installation of brass outer collar - I think I 
know the answer here - I installed it by cutting a 
small outer collar to rest up against the hull and 
enclose the inner mounting tube (to give a 
bearing surface for the stand that was not the 
ship bottom). However, I applied cyanoacrylate 
to the inner tube and slid it on, and it stuck 
about a 0.5 mm out from the hull (fast drying 
^%$$!!), I'm assuming that I should get some 
slower drying glue here.... 

3) Installation of brass stand into old GeoHex 
base. How do you gaurantee verticality and 
perpendicularity in both relevant axes? Any 
tricks? I was thinking the application of some 
more plastic metal at the joint would also be 
wise to reinforce it.... but it might be 
unaesthetic. Strikes me that one basedepth is a 
small contact area for a 90 degree join...?

Thoughts and input appreciated. The concept 
seems very cool.... I obviously just need to 
refine the implementation so it is faster and 
more effective. 

Tomb. 
---------------------------------------------
Thomas Barclay
Co-Creator of http://www.stargrunt.ca 
Stargrunt II and Dirtside II game site

No Battle Plan Survives Contact With Dice.
-- Mark 'Indy' Kochte