Hello fellow smiths,
I would like your kind help for a problem that is bugging me. For a fastening system I want to use a slot punched hole in Round bar and a wedge to hold everything together. As I need to make a few (30+) and never made any I would like to get your experience what is best. The main problem is the minimal distortion in the bar because I want to get it through a 1/2 inch hole.
My ideas so far are:
1. Drilling most of it out and punch the rest hot
2. Forge the ends in a shallower half round swage, bend it over and faggot weld it to get a hole at the end.
3. Take thinner square stock and thin the hole section to compensate for the swell
I added a picture and hope it makes sense