Half the Mounting Holes Drilled Out to 3/8"

[FOR_Star]

Acquired a new-to-me Star Universal.  Everything looks original and in good condition, but does need a good cleaning, fluff & buff, and lube.
I'm curious as to why a previous owner would drill out the two "front" mounting holes to 3/8".  Has anyone seen a mounting arrangement that needed the front holes opened up to 3/8"? Some sort of quick-disconnect arrangement?

Could make using a Ray-Vin indexer more challenging, I guess.

[rbwillnj]

Sometimes people just don't have enough 1/4" bolts in the drawer.   I have seen several where the mounting holes have been enlarged.

Since only the two in the front mounting holes have been enlarged, I would guess it had something to do with mounting an indexer.

[FOR_Star]

Yeah, those pesky 1/4" machine screws. HaHa

Surprised the OEM Star mounting bolt wasn't a 17/64-28 UNS. (an attempt at a little SMW over-engineered humor)

[FOR_Star]

Any thoughts on a somewhat reasonable way to return these two holes to their original dimensions? (1/4" hardware, with countersink)

[Richard Hubbard]

Just replace the base. 
Star Machine Works should have replacement bases.  At least they did when I inquired a few months back.

[FOR_Star]

Just replace the base. 
Star Machine Works should have replacement bases.  At least they did when I inquired a few months back.

That is one way.  I'm sure Bruce could fit a new base if I sent it back to him.

Does anyone know if the base is cast aluminum, or is it cast zinc-like metal similar to the powder slide housings?
And, if aluminum, could a welder experienced in aluminum welding close up the holes so they could be re-drilled and countersunk? (obviously, without FUBARing the base)
Bruce and/or Dave, any thoughts?

Thanks,
Warren

[Dan]

I would just press bushings in or drill and tap for bushings before I welded on Aluminum.

You would have to TIG it and remachine. The work likely exceeds the cost of the part.