You neglected to mention the other option:  Purchase a new
bolt with a cotter pin hole. In the smaller sizes they are
less than $1.00.  Aircraft Spruce & Specialty is a good
source, but a local FBO will probably have an assortment.
Also, if you are working on your own plane, "AC43.13" tells
all about "Acceptable (to the FAA) Techniques," including
questions such as the one you asked (it's also available
mail order).

David
N6359V


Jack Lewis wrote:
> 
> Here's a question for ya.
> 
> I have a damaged bolt.  It is a bolt with a cotter pin.
> I have another bolt the same size, without a cotter
> pin hole.
> 
> How can I LEGALLY replace the original.
> 
> With a bolt and nylon lock nut?
> With a bolt and I drill a hole into it for a cotter pin?
> 
> The reason I ask is, I've heard it is illegal for me to
> drill the cotter pin hole.
> 
> Anyone out there who may have knowledge that can site me
> the correct data?
> 
> Thanks
> Jack
> 
>
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