Barcor Chamfer Gage
the original chamfer checking gage made in USA






This Barcor chamfer checking dial gage will give you a direct reading of the outer diameter of a chamfered hole. The larger gages such as the one shown above, have 3-winged plungers. Smaller gages are also available with full conic plungers.

  • The Chamfer Gage only measures the top major large diameter of the chamfered or tapered hole. Hence, when you put the three blade Gaging Plunger into a sharp cornered (0º) Master or part, the gage reads the top diameter, which in this case is a straight hole. As you use it on a chamfered part having an angle less than the angle of the Gaging Plunger, the gage still picks up only the top major diameter, and so any angle up to the 90º included is correctly measured. Mind you, we are NOT measuring the angle or the depth of the chamfer, just the top diameter. Likewise on the 90º-127º Models, any angle from a straight hole to the 127º will be read correctly. So WHY have two Models? This is because the 90º has a 2:1 ratio and the shallower (harder to centralize and read) 127º has a 4:1 ratio and correspondingly an indicator twice as sensitive. Since most chamfers are 45º (90º included) the 90º gage is better and easier to use.Two forms are available: for chamfers with an angle of less than 90° and for chamfers with angles from 90° to 127° — usage desciption as provided by the manufacturer

The standard dial indicator is graduated in .001" but also available with .0001" digital or .0001" mechanical graduations. The accuracy for reading chamfers is ±.001" on 0-90° models and ±.002" on 90-127° models, regardless of which indicator you use.

The base of the Chamfer Gage is manufactured by Barcor (USA) but the dial indicator varies from supplier to supplier. You'll most often find this tool with a Starrett indicator or a CDI indicator, usually with a vanity dial. AccuPro Gold Chamfer Gage, SPI Chamfer Gage, Starrett Chamfer Gage, Dialsink (Brunswick Instrument) and the Dyer Chamfer Gage are examples.

It's a sturdy gage with a cleverly simple design. It does require "mastering" and this is done as follows: on the back cover of the gage you'll find the words "Set To" followed by a value, such as .020. Now it's a matter of setting the gage to this value while it's being held flat on a surface plate (the plunger pushed all the way in). We suggest you inscribe this value into the metal or plastic back cover because the label will eventually wear off. Unless you've lost this value, no other setting masters are needed.


Barcor .001" reading for 0-90° angle


.001" models can be used for direct readings of holes with chamfers less than 90°. The chamfer gage will have to be pre-set according to instructions provided with the instrument. Setting rings are not necessary. Larger ranges are available on request.

Feel free to click on the Starrett number below to compare pricing and features.




Diameter Range


Barcor List price

Your price




0-3/8" (conic)**




BAR 0090



0-3/8" (3-winged)







0-1/2" (conic)**




BAR 5090



0-1/2" (3-winged)




BAR 1090



0-1" (3-winged)




BAR 2090



1-2" (3-winged)




BAR 3090



2-3" (3-winged)





* The 0-1/2" model is rarely in stock and may require up to 6 weeks for delivery. May we suggest you get the 0-1" version instead? It will give you a wider measuring range and it costs less. Model 1090 is usually in stock.

**While larger chamfer gages have 3-point contact with a 3-winged plunger, model 0090 FC and 5090 FC has full conic contact giving greater reliability. This is often the gage preferred by the aeronautics industry and is usually in stock.

Barcor .001" reading for 90-127° angle


.001" models can also be used for direct readings of the major diameter of a chamfered hole with angles greater than 90°. The chamfer gage will have to be pre-set according to instructions provided with the instrument. Setting rings are not necessary. Larger ranges are available on request. SPI and Starrett numbers are shown for cross-reference. (Feel free to click on the Starret number below to compare pricing and features.)





Diameter Range


Barcor List price

Your price

BAR 0127



0-3/8" (90-127°)




BAR 5127



0-1/2" (90-127°)




BAR 1127



0-1" (90-127°)




BAR 2127



1-2" (90-127°)




BAR 3127



2-3" (90-127°)




Is there any leeway in the measuring range?


Is there any leeway in the measuring range? Not really: the range is only slightly extended. For example: the 1-2" range actually measures from .950" to 2.040"


Setting masters without chamfers


What if someone insists you check the chamfer gage against a master ring? This will work only if the ring does not have any chamfers. It's also the only way to recover the "Set To" value if it's been lost.

Standard master rings, which you may already use in your shop, all have a slight chamfer. If you're not convinced, use a magnifying glass. The chamfer can be removed by grinding the surface of the ring. Only trust a master machinist for such an operation since these rings are too much of an investment to toy with.

If you routinely use your chamfer gage for just one dimension, then you may want to invest in a custom ring of that particular size. If you use multiple ranges, then we suggest getting a setting ring for the middle of the range as shown below.

There is no difference between masters used for 0-90° or 90-127° gages.

Super .0001" Chamfer Gage


The .0001" models can only be used as a comparator. You will have to set the indicator to your master piece and then compare your work pieces. Direct readings will not be possible with the .0001" chamfer gage. Please inquire about prices.

Metric Chamfer Gage


All models are available with mechanical metric indicators. Please inquire about prices.

Spare Parts and Repair Service


Repair service for chamfer gages is available from Long Island Indicator Service. In the event that the indicator is damaged, it is also possible to buy a replacement. Digital and mechanical indicators are also interchangeable. In other words, you can switch from one to the other. The replacement indicators below are suitable for all inch ranges. They are not suitable for metric readings.

The following parts are not available from us. The part numbers are shown for reference only.

  • Replacement indicator 90° ... part no. BAR10910
  • Replacement indicator 127° ... part no. BAR10710
  • Replacement digital indicator 90° ... part no. BAR10910-SPC
  • Replacement digital indicator 127° ... part no. BAR10710-SPC
  • Replacement conical plunger for model 0090 ... BAR55950
  • Replacement 3-winged plunger for model 1090 ... BAR11951
  • Replacement 3-winged plunger for model 1127 ... BAR11751
  • Replacement 3-winged plunger for model 2127 ... BAR12762
  • Replacement 3-winged plunger for model 3127 ... BAR13962


What will go wrong?


What will go wrong? The base of the Chamfer Gage will probably never fail you. If the 3-winged gaging plunger becomes damaged or worn, it can be replaced without any special tools. Simply unscrew the knurled ring, remove the old plunger and reassemble. More than likely, you will find that the indicator no longer functions. In that case, just buy a new indicator and you can replace it yourself.

Since neither Starrett nor CDI makes a particularly durable indicator, chances are you'll eventually damage the teeth on the rack. This can be repaired or replaced. These indicators have special ranges, so you can't simply insert another model into the base. As mentioned before, you may end up forgetting what the "Set To" value is if you don't write it down or permanently mark it on the gage.

Why doesn't my chamfer gage repeat?


There are two reasons why the chamfer gage readings may not repeat. The first is operator "feel" especially if the angle is greater than 90º and you are using the much shallower 127º models. The other reason is the nature of the part. If the chamfer diameter is not concentric or true, you will encounter poor repeatability. — manufacturer's statement

Suggestion: practice before you begin to take readings. Take many measurements until you notice that you've gotten the "feel" and that the readings are beginning to repeat. Then compare these with a co-worker—or two—until you get a consensus. Unfortunately this kind of measurement is not as absolute as we'd like and - as you've noticed - variation is to be expected. You will have to establish acceptable tolerances not only for the chamfer but also for the operator's shortcomings.

The guaranteed accuracy of the 90º mechanical gages when used in a NIST traceable master is ±.001", a total of .002", and ±.002", a total of .004" for the 127º models. 





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Long Island Indicator Service Inc
14 Sarah Drive
Hauppauge NY 11788 — USA

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This page's most recent revision: 13 December 2018
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Original photographs and content copyright 2018 by JWGrum



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