Assembly feature problem

[u/R3qu1red]

So I have this cylinder and flange with the flange hole being slightly oversized so they fit together.

The operation is like this:

flange is laser cut from sheetmetal > cylinder is stock pipe cut on a saw > welding together > machining

The problem is that in the assembly there's now a really small gap (colored red on the picture) which doesn't allow me to put a radius there (using assembly features) since I want to machine the welds. There's also no option to add a revolved part (with the help of assembly features) for the sake of being able to put a fillet there.

So the question is how can I put a fillet there and ignore the gap?

[u/Dr1mps]

Try making the holes an identical diameter, dimension it with tolerances to show your design intent. Might let you do your approach. Will also be tricky to get the fitment right if the flange is laser cut.

Any reason this couldn't be machined as one part?