Best Way to fill a hole?

[joeeng]

as part of a project I have some 12mm square solid stainless. I have drilled a through hole but it is on the wrong axis (90 degrees out) compared to other parts on the square bar.

What is the best way to fill this 5mm hole, so that when I drill the hole in the correct place on the other axis and can still be tapped m6 and maintain strength in the bar?

I was thinking make a pin to fit the hole, counter sink each side of the hole and weld the pin in then machine the surface???

Thanks

 

[Tiggy_dorset]

I was thinking make a pin to fit the hole, counter sink each side of the hole and weld the pin in then machine the surface???

Thats the way I would probably attack it. Bear in mind the welding may distort the bar so may need straightening if its critical

 

[piman]

Hello Joeng,

that's as neat a way as any, although 5mm could just be welded over anyway. Even if pinned it won't make the bar any stronger.

Alec

 

[joeeng]

Hi Tiggy,

Thanks for the reply, this is what I have done. Also yes fit is critical as it is a sliding fit inside of another piece.

I had it clamped to the table in 3 places, welded one side, let it cool naturally, then done the same with the other side. machined the surfaces and checked the sliding fit, it had a little bit of drag due to a very very slight bend, small tap with the hammer and its perfect. Hope it drills and taps ok when I do the hole in the correct position

 

[joeeng]

Hello Joeng,

that's as neat a way as any, although 5mm could just be welded over anyway. Even if pinned it won't make the bar any stronger.

Alec

Sorry Alec, got mixed up with my posts before.

I had some practice of different techniques on a piece of scrap and tried just using filler on a 5mm hole. I then cut a cross section and basically had weld caps at either ends of the hole with the middle still hollow.

Is it possible to weld up the hole using filler and been able to 100% fill the hole. I am just picking up tig so it may be my technique that is wrong.