Going to shink a hole in my trans sep.plate from 1mm to 0.6mm

1. Use a TIG weld to melt the hole and then redrill it
2. "hammer" it closed and redrill it

theese two options feels unsafe since drill with a 0.6mm drill through a steel plate doesnt sound like a good idea...

3. make the hole bigger ( 2-3mm ) and countersink it on both sides with a 4-5mm drill then fill it with a softer mtrl and then drill it sounds better.

What should I fill it with?
- tin is easy but will it hold?
- al. sound better but how do I melt it or do I just hammer it out? ( dont have a AC/DC TIG )

any tips? before I start

 

Trans-Go supplies aluminum plugs to fill holes. It is as you mentioned, counter sink each side a little, place plate on flat hard surface, gently mash plug with small hammer to fill.

As you only need to close up the hole a little, may be able to use a ball peen hammer and tap around the edge of the hole. That will displace metal into the hole making it smaller.

RBob.

 

thx.......

after testing on another plate

I took the TIG and welded it (20amps +added very little mtrl ) then redrilled the hole.