May need some pointers. Small parts.

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Old postage meter base part.  Thin steel of unknown alloy.   About eighteen guage.    Small, approx. 1/2" diameter short barrel which locks into a slotted hole.  Appears to be electrically resistance welded.   I'd like to try to mend it.  A new one costs my company $250.A tiny bead is acceptable so long as there is clearance for the plate that locks under the barrel's ears.    The center hole of the barrel must remain clear as does the bottom of the plate.http://www.weldingweb.com/attachment...1&d=1202873345http://www.weldingweb.com/attachment...1&d=1202873345http://www.weldingweb.com/attachment...1&d=1202873345And what it's supposed to look like. http://www.weldingweb.com/attachment...1&d=1202874418 The rotational position of the barrel's ears is critical.  That's gonna be a best wild gues at best.  There is enough residue behind to help align the two pieces.Here's what I got:  Miller SW200, .040 ceriated and pure argon.Get the Cad off.  Too small for filler.  A cratered concave weld is fine so long as it's stuck.   The way I usually do something I don't know is to start with about the same type and size test material and tweek the machine using the test material.  Once I'm sure I'm in the ball park, I move on to the real piece.Any suggestions? Attached Images
Reply:OK.  I'm still learning picture posting...........
Reply:Pics are up.  Unknown material, You could try silver braize.DavidReal world weldin.  When I grow up I want to be a tig weldor.
Reply:Originally Posted by David RPics are up.  Unknown material, You could try silver braize.David
Reply:I agree with David.If you knew what material it was could you have ground a small bevel on the lug and tig weld it? or drill some holes in the plate and plug weld it?I may  be missing something about the fit up,but thats how I would be looking at it.If it's too . get an office jobLincoln wp225g7 Lincoln 250 idealarcFrankenstein O/A set-up Weld-tech  tig set-upLincoln sp 175 plus profax  arc gouger
Reply:Silver solder looks like your best bet. It's pretty tough stuff. Welding isn't always your best option.The difference between art and craft is the quality of the workmanship. I am an artist.