Problem with metal frame not aligning holes

[completematrix]

I'm putting together a metal exercise frame.
2 parts won't align. I can't push down any further.
Guessing it's a manufacturing fault.
I can't send back.

See pic below.



Any ideas how to fix?
I thought of drilling. Then I thought filing would solve. I don't have a metal file though!

 

[Wayners]

File off the end of top peace. It will then drop down a bit and hole will line up..
You will have to ask about for a file or buy one for about £6
Hole file set is about £3.50 if you wanted to try that.

Unfortunately as you say. It's mass produced stuff with faults sometimes

 

[completematrix]

I've got a file set for about £4 from screw fix
They're absolutely tiny!
I need something with a handle else will be a long time filing.
I need to file down 6 holes

 

[freddiemercurystwin]

You can sometimes get full size files in Poundland and the like, depending on their stock, obviously crap but suitable for one-offs like this.

 

[freddiemercurystwin]

Or use a drill to enlarge the hole.

 

[Burnerman]

Can you split the joint, rotate it 180 degrees and try again?
John

 

[Alec_t]

If multiple holes are mis-aligned then, as per post #2, file or cut off 1mm or so from the end of the top piece. Hopefully all holes would then align.

 

[Notch7]

I need something with a handle else will be a long time filing.
I need to file down 6 holes

Chainsaw file

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Or just use a slightly bigger HSS drill bit in one of the holes.

Just make sure you do the same hole in each part so you don’t get one leg up and one leg down

 

[foxhole]

Dismantle , spray with wd4 , reassemble, if still misaligned use a screwdriver in hole to lever into position .

 

[Exedon]

Dismantle , spray with wd4 , reassemble, if still misaligned use a screwdriver in hole to lever into position .

Or if your feeling posh use a podger spanner.

 

[cdbe]

Hammer and piece of wood to tap them together a bit more.

 

[Lower]

Get a smaller diameter bolt.

 

[completematrix]

The pieces won't budge.
Smaller bolts I think is a good choice.

 

[robinbanks]

The metal doesn't appear particularly thick. I too second the earlier proposals of:

1: see if the holes line up any better by rotating just one of the pieces 180 degrees; maybe they are at a slight angle
2: rotate them slightly to better align them along the vertical line,then use a hammer to persuade the joint to tighten up

 

[just pumps]

Fit every bolt loose until all bolts are in holes and then tighten up.