Join Date: Oct 2006
Location: Callao, VA
Thanked 20 Times in 20 Posts
Rep Power: 11
If any repair is made, I would opt for a sleeve and welding, by a metals familiar welder. The added rivets and needed drilling in the 4"x4" area(small), may actually weaken the mentioned 1/4" hole area.
Ultrasound of the entire extrusion is the best way to actually know what is going on...anything else is a guess or speculation at best.
If not, you may want to purchase an inexpensive bore camera and see what is going on inside.