To fit two bits of metal together where the holes don't quite meet up, so I want to turn one hole into a bit of a slot. Holes are 1 inch and about 1/4 inch out of line.
Thinking some kind of grinding drill bit, but my google foo isn't coming up with anything suitable.
Jigsaw?
drill more holes and use a half round file to neaten it up?
It is only a small adjustment needed, just to elongate the hole down by about 1/4 of an inch, but it is too awkward a shaped object to clamp and file by hand.
Dremel with a drum sander or a burr
What thickness of metal are you joining
How thick is the material you need to remove material from?
Round file, or carbide burr (ideally in a die grinder).
There's a selection of problem solvers here... top left is the one
Round file if it's small, die grinder if it's bigger. If it needs a really long slot, drill a second hole (or more than one) and then join em up. Dremel if you have one, it's not really the right answer for anything but it's a reasonable answer for a lot of things
Or, just horrifically bodge it with a drill bit and angle and sideloads
Depending what it is drilling the holes oversize and using washers might do it?
Track saw.
File.
Podger
But, seriously, how thick and what metal?
Can you not make both holes a circular 1.25"?
Podger
lined a few holes up with one of those in my time…
Or if that wasn’t working then get the hole saw or the reamer out 😎
To join 2 bits of metal together? Welder.
Podger
lined a few holes up with one of those in my time…
Dirty bugger... 😯
