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Old 12-08-2011
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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.
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