Abstract: A method for repairing minor defects in a workpiece using flame spraying is provided. The method includes first providing a workpiece having a defect and an area proximate to the defect. The method also includes routing a portion of the workpiece, including the defect, such that the routing removes at least a portion of the workpiece proximate to the defect. The depth to which the workpiece is routed may be controlled with a micro-stop countersink apparatus. A router bit is generally plunged into the workpiece in a direction orthogonal to the surface of the workpiece such that the routed portion of the workpiece defines a sidewall extending generally orthogonal to the workpiece and a conical bottom surface. The portion of the workpiece that has been removed by routing is then flame sprayed such that new material is added to fill the portion of the workpiece that has been routed.