Have a shop certified to do this type of work, fill the holes with the
same material. They will expand the part, then put the filler in
(maybe oversize round stock) and when the part returns to normal size
it will be as strong. Aircraft manufacturers do this regularly, but
they're set up to do it.


On Sat, 16 Oct 2004 23:31:18 GMT, "Dick" wrote:

I was thinking that welding would ruin the temper of the gear leg and I'd
like to salvage it; talking 2 of 4 bolts and could drill another in a new
location.


"Orval Fairbairn" wrote in message
news .
In article ,
(Drizler) wrote:

"Dick" wrote in message
. com...
What would be a way to fix a mismatch in holes in steel without
ruining
the
temper? Specifically a main gear leg which it bolts up to a plate .
Two of
the four holes are about 1/3 diameter off. The bolts are 3/8" od.

Possibilties, as I see it, a elongate existing holes in one part to
fit
the 3/8" bolts; drill new 3/8" holes in new location; install 1/4"
bolts in
mismatched holes. I don't have access to tooling
or machinery that could drill out the holes to say 9/16", thereby
replacing
the 3/8 with bigger bolts.

Any advice would be appreciated.
Thanks, Dick

You could go with a larger bit in a standard 3/8 drill by buying a
larger bit with a cut down shank. A bit more pricy and harder to get
but surely at lowes or a true value hardware. One of those stepped
bits would do it as well. If its not thick or hardened a tapered
reamer would work but it would be slow and have a slight taper to the
bore.


Why not replace the plate, or, weld the hole in the plate shut, weld in
reinforcing to the plate, and redrill?

Elongation and using 1/4" bolts are a non solution -- especially in a
landing gear installation.