Messed up D Nuts for header attachment

[ModelAJim]

Guys this isn't my actual pic but the screws for the header broke and I had to drill a couple out . Well one got a broken bit and now the hole is offset. I ran a tap in it but it looks like crap. Functional but crappy. Has anyone ever drilled them out and welded plugs?

Or other ideas?? I can't get to the back.

Maybe I could drill them out and fish a wire down to pull new ones and tack them on the front?

 

[Brentwood Bob]

Oversize?

 

[Oldbluoval]

I had that happen on cabriolet. Welded up and re-tapped. Not easy
I used a bottom tap as the area is not deep.
I considered cutting out the front and feeding new d-nut and the patching. I could make that happen but didn’t…not out of the question.

 

[ModelAJim]

Here's mine...one side is ok the other is pretty bad. I may try to fix better after I sandblast. or should I say its good enough??

 

[Brentwood Bob]

At this stage, I would make a pattern from a tracing to get accurate placement. Figure out how to index it because you will be fitting it a few times. Looks like fun.