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I don't think the filled slot would have any effect on tuning, but if the slot is too shallow the string could slip out with a hard strum.
Each of the items listed in your final paragraph could contribute to tuning instability. Taken together they're a recipe for disaster. You can get adapter bushings from Stewmac to make your Klusons fit in the 10mm holes.
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Bud Veazey
"Chisels are calling. Time to make sawdust."
--Mark Knopfler
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