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@Oswald
There's still material to come off that by joining the holes and making a slot .. so round two you can make it neater and polish or paint it.. this is what I was alluding too (from a World Cup XC bike)
On the fork .. Are you sure the brake bolt is long enough and / or the correct one? The reason I say the later is I had some Reynolds Onza forks that used a Reynolds brake bolt and any other would not fit correctly.
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