I was in the process of altering the size of the front sight hole on my Mossberg 590.  I was facilitating the hole to accept a larger threaded night sight.

Well, I screwed up and made the hole too big.

How do I correct this?  I currently have no front sight and an open hole in the front of the barrel.

Thanks for any help.

How much too big? You can work wonders with some of the new adhesives out there, but in this case it might also be necessary to bush-up the sight post first with some sort of material such as fine copper wire, etc. Also, Brownell's sells bead sights of many different sizes, although this won't allow use of your current n.s. front post. I might just resort to a good gunsmith here, since you already have the investment in the sight.

If you have a tap 'n' die set you could just re-thread the hole an thread a piece of brass round stock to fill the hole. just be careful that the it is flush with the bore or you could creat even more problems!

Since it will just be holding a bead and not really under a lot of stress, you might try filling the hole with Brownell's Acra-Weld epoxy or JB Weld, let it set up, and then re-tap the hole.  I know others who have had good luck doing that.

I appreciate all the advice.  I went with the JB Weld.  Thank you!