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Bob Engelhardt

wrote:
... 800 holes, 5 mm. Which have to be
closed. ... Filling the
holes with some epoxy based filler would have been easy, but after
that it is impossible to sand blast, which is really necessary ...

800 holes!! Yikes. If you can't sandblast after filling with epoxy,
could you sandblast first, then fill with epoxy? The holes are only 5mm
and if the blast stream isn't exactly perpendicular, there should be
very little penetration of sand into the hole.

If you rule that out, the Sawzall (reciprocating saw) with a bimetal
blade is the way to go. Faster even than the abrasive cut-off wheel.
If you don't have one, it would be worth the investment just for this job.

Bob

BTW - in case you don't already know this, to do the tapping, use a
spiral-point tap in a drill. 6mm should be small enough to not slip in
the jaws. (800 holes!!)