Originally Posted By: Pablo
It's a cast Al cover, not a lot of mm's thick.
A regular bolt can make a good plug, but the challenge is attaching a nut to screw it into...
You can't weld the steel nut to the Al, and you're probably looking at assembly by some kind of compression. And don't have room for the typical size nuts on the inside of the cover...
Residential light fixtures usually come with an (approximately) 1/2" x 3" fine threaded steel nipple, and some nuts for it that are about as thick as a typical washer.
You could weld a (regular nut & bolt type) nut onto one end of the threaded nipple to give yourself internal threads for a plug (bolt). Use a nut with an ID < the ID of the nipple (so your plug can go inside the nipple a little), and an OD > than the OD of the nipple (for sealing - more on that below).
Then cut the nipple off so you have just enough to put through your Al. cover. Use one of a thin nuts inside the cover, and an o-ring on the outside (smashed between the AL and the larger welded on nut).
If I could draw a profile view picture, the order of stuff, from inside to outside is: thin nut (screwed on to nipple), Al cover, o-ring, regular nut (welded to nipple). Then a bolt screws into the regular nut.