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I want to have some extra aluminum welded to the interior of the plenum (the outer 8 most bolts, 4 on each side) to provide a little more clamping force and help prevent stripping of the threads. I also want to do the same process for the inner 8 bolts, but have the runner flange welded/tapped instead so the bolts go in from inside the plenum. I would then cross-drill those bolts to accept a retaining wire or small cotter pin to prevent them from loosening out into the plenum and being eaten. I think others have done this, but what should I expect as far as machine shop costs are?
I plan on looking around but would like a good starting point for the minor welding/drilling of the bolt holes. I would even tap them myself once they were drilled properly (and to avoid potential confusion...)