I see, it looks like the hole only needs to be enlarged a very small amount.
Can you measure how much?  It looks like 1mm diameter change or less.

I believe that a cylindrical sanding bit on the end of a Dremel tool will let
you enlarge the hole by the amount you need, and since your axle has flats, you
only need to enlarge in one axis (top and bottom of the hole) and that will be
easy.

I have a dremel and bits at sudoroom and i'll be there tonight, i can check on
it and see if i have the bits i'm recommending to you.

-jake


On Tue, 3 May 2022, Andrew R Gross wrote:

> Pics:   https://photos.app.goo.gl/isAxJf35G6QHzn9eA
>
> How would I make an adapter plate? I'm thinking that I'd need to mill out a
> hole in a thin block of steel for the axle and then another for a bolt
> sized to the current mounting piece, then bolt it together. Thoughts?
>
> *Andrew R Gross, (he/him)*
> 412.657.5332    -   shrad.org <http://www.shrad.org>
>
>
> On Tue, May 3, 2022 at 2:17 AM Jake <jake@spaz.org> wrote:
>
>> send links to pictures (rather than attach pictures to the email) of the
>> bracket, and the bike where the bracket needs to go.
>>
>> I am picturing either attaching the bracket to the bike frame not on the
>> axle
>> itself, or making an adapter plate that fits onto the axle and bolts onto
>> the
>> original trailer plate.  But I need to see it or see pictures.
>>
>> also I have an oxy acetylene cutting torch if you really want to make the
>> hole
>> bigger :)
>>
>> (that would happen at my house)
>>
>> -jake
>>
>> On Mon, 2 May 2022, Andrew R Gross via sudo-discuss wrote:
>>
>>> I bought a really nice bike trailer I'm so excited to use, but the
>> mounting
>>> bracket hole is too small for the axle, and the mounting bracket is made
>> of
>>> hardened cast steel. I have a crappy cheap bike trailer that had the same
>>> issue, and I was able to widen the hole with a hand drill, but this new
>> one
>>> I couldn't make a dent in with a drill press. I need advice.
>>>
>>> Can I drill it? If so, how?
>>>
>>> Can I mill it or turn it? If so, how?
>>>
>>> Does anyone know of a machinist who can do this, or can anyone do this
>>> themselves for compensation?
>>>
>>> Is it possible to replace this with another one that fits the axle? Or
>> make
>>> and adapter that fits the mounting bracket and the axle?
>>>
>>> The bike is electric, so the axle contains wires and can't be replaced,
>> as
>>> far as I know.
>>>
>>> Any advice would be appreciated. I really want to use this.
>>> *Andrew R Gross, (he/him)*
>>> 412.657.5332    -   shrad.org <http://www.shrad.org>
>>>
>>
>
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