I would have just gotten it welded. I've had both a hole welded shut and a bung welded on the stock cast headers, and never had an issue, nor did the welder complain about doing the job. Had it done years ago at the muffler shop next door to Indy Auto (I think that's McVay's?).
It probably would have cost you less than the price of that nut and bolt to get the hole closed, and it would have been less work just to take the header off and bring it to the shop than all the non-sense w/ cutting bolts, tapping holes, trying to get a washer to seal, etc.
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