I have a metal part of a bandsaw that had a machine screw head break off. I drilled a hole and used an extraction bit and it also broke off. Due to poorly executed attempts to drill again (so I can tap it), the surface is now irregular enough that the bit (and chuck) of my drill press wobbles out of place. I thought I might melt the surface to level it out, but the Propane torch I bought doesn't seem to get hot enough (after 3 minutes of leaving the flame on the metal). I contacted a couple machine shops and they aren't interested in this tiny job. Any suggestions on how I can get a centered hole drilled in this thing? Also, should I be trying to drill a larger hole than was there, since the integrity of a same size hole would be affected by the previous hole?
Edit: You can see the part [here]. It is 2 5/8" long. The one I have is steel; the potential replacement is not exactly the same shape and appears to be soft metal. It would be over $50. (I've spent about $40 so far trying to fix it.) The problem area is the rightmost screw hole in the photo, which is currently filled with metal from the top to about 80% of the depth of the original hole. There is no access to it from the other side. (The bit would have to cut through metal on the far side of the bit and air on the near.)