Ernie, help!

I'm not Ernie, but its my understanding 7075 is not easy to weld. Would a bushing help for this application?

So, 7075 is sort-of non-weldable in structural applications, though it is noted that 7075 is routinely welded in injection mold repairs. It appears that 4043 filler which I have on hand will do the job, and there really aren't any notable loads on the part. I'm still considering other possible options, the holes are about .095" oversized. At any rate, I'm out of town for a week, so I have some time to study the options.

You will need to preheat the whole piece to above 500 degF and slow cool afterwards.

The only time it is welded in Aerospace is by laser or friction stir.

I'll investigate if I can sleeve the holes or something. It seems if I do weld them, the whole part or much of it ends up in a T0 state. Given the negligible loads that's probably ok as long as I don't have cracking issues.

It looks like I can get drill bushings the correct ID and just a hair larger OD than the current holes. Perhaps those would do the job ground down to the correct length and press / Loctited into place.