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Cake day: June 13th, 2023

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  • Gotcha, it sounds like it is fine to have a little extra clearance on the ID, which helps us here. I do recommend flipping the piece and squaring it back up best you can. If you have enough meat to start a short, stiff, small diameter center drill from the offset end, you at least know they’ll meet approximately in the middle.

    Keep the dia small for as deep as you can go with wall thickness between the new hole and the old, offset hole. Then step back up to your smallest diameter drill that’ll reach like 1/3 of the way through the part. Keep the speed per guidelines with the material, but turn those feeds down super slow. The drill WILL eventually jump back into the existing hole, probably breaking the drill in the process. The goal is to get as deep as possible.

    This is a challenging task for the equipment you’ve been given. Don’t beat yourself up about it. Next time they want something like this, make four of them at 1/4 the length and weld them together.