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[Nick W]

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Once through, enlarge the hole with successive 0.5mm bigger drills until hole is big enough to accept bolt.

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Each to their own, but in my experience, going up a size as incremental as that is more likely to end up with the drill snagging ..... better for the drill to have something to cut.  I'd do it in one go 

0.5mm increase with a handheld drill sounds like a recipe for broken drillbits to me. I wouldn't do that in the lathe or mill either, you'll just be scraping the hole bigger rather than cutting it. And that's not good on a nice piece of steel; on a grotty piece that's been an exhaust for several years you'll really struggle.

Filing the initial surface flat was good advice though!

[Nick W]

It's not a given they'll do it or even let my car in. I know I've got a quiet day tomorrow so will be sat in yard for a while. Going to give it the "can I borrow a bay and some tools" and hope they say "chuck it there, I'll get them out give me 2 minutes".

Mention that you've left a spare pack of beer on the driver's seat when you speak to the fitter. Most non-professionals make exhausts really difficult by pussy-footing about.

[omega3000]

So file flat "angle grinder" then centre punch and 2 stage drilling 

[GastronomicKleptomaniac]

I've seen excellent results from a plasma cutter followed by a drill. I sadly can't justify ownong one, or indeed a 2woody to operate it... 

[firemoth]

Got it sorted. Those bolts took a hell of a lot of drilling woo l with the air drill too. Ended up breaking out the brand new drill bits. 2 hours over a pit and I've finally got a fully connected exhaust again

[TheBoy]

Got it sorted. Those bolts took a hell of a lot of drilling woo l with the air drill too. Ended up breaking out the brand new drill bits. 2 hours over a pit and I've finally got a fully connected exhaust again

Its a bit of a ballache - not difficult, just tedious.

Personally, I drill a pilot, then drill to size, then tap

[firemoth]

I did pilot, then drill to size, but didn't tap. I've nut and bolted it

[Raymienets]

Had the same problems a few weeks back. Got a supply of 3mm drills and started but not putting to much pressure on it. It will eventually go through. Then increase the size of the drill.