Thanks. I’ll check it out. This was the first time it happened. I’m sure it won’t be the lastYou could consider some of the alternative gauges that Doc Green has documented on his website in the Gauges section of his Articles webpage.
I would love to say that I have never had the inside diameter exceed the outside diameter, but that wouldn't be accurate.
Good luck!

I mounted a drill bit in a handle


Good idea. I’m going to do that.The stop collars are nice because I don't have to watch the bit carefully and try to remember which Sharpie line is the right one!
I have o-rings on my depth drillsThe stop collars are nice because I don't have to watch the bit carefully and try to remember which Sharpie line is the the right one!
blackforestwood.com



That’s what Mike Jackofsky does.I guess the only other method would be if there is air in between your grip on the tenon and you can slip a caliper in the gap.
Using millimeters would greatly simplify the calculations.Math can be challenging when fractions are involved. What I actually do is to subtract the distance from the headstock to the jaw face from 14" and write that on my chuck. So if the distance is 9 5/8", I write 4 3/8" on the chuck. When I measure, if the distance is greater than 4 3/8", I've already made a funnel. If it's less, you can see right on the tape measure how much room you have left before you hit 4 3/8". That the bottom thickness.
Using millimeters would greatly simplify the calculations.