Thread: Have I brought a lemon?

That oversized hole can be filled up, eazy-peazy.

Find a length of brass rod which will just slide down into the hole. Cut this off only very slightly longer than needed (about 0.5 - 1.0 mm extra).

Insert this bit of brass rod into the hole and start peening lightly (working from both sides) to expand it so that the brass will expand into the hole.

Once it is as secure as can be, carefully file away any bit of the brass which stands proud of the surface. I suggest using a very fine cut file with light strokes.

Once this process is complete, you need only redrill the correct size of hole for the rivet pin you plan to use.

If you are at all in doubt, you could also use some quick set epoxy when you insert that bit of brass prior to the peening, but I haven't found this to be necessary.