I like AX's idea..

 

Well, I'm happy to report that this was one of those rare occasions that the result of a repair exceeded my expectations. Here's the damaged hole after the remains of the bolt and all the corrosion were removed. It was even worse than I though after it had been cleaned up. The dark area on the left of the hole is the original threads.



And here it is after JB Weld, drill, tap, and heli-coil. I was really surprised at how well the JB Weld tapped.



If anyone is really that interested in the procedure, I added a step-by-step to my gallery. Thanks again for all the advice. I still think that welding the hole up would have been ideal, but this looks like a good, solid repair. Plus it was easy and free!

 

Nice.. and nice gallery too.. I'll keep this one in the list for potential use..

Where did you get the helicoil?

Sam

 

We have used this repair on magnesium timing covers and bell housings. It's a pain to get magnesium welded, and it costs too much to replace just because of a bad hole, so we started doing this. Never had any problems with one.

Enjoy,
SPark

 

Sam,

I get my heli-coil kits from NAPA. My local store keeps the kits in stock for quite a few different thread sizes. The kits usually come with the special tap, an installation tool, several coil inserts, and occasionally the necessary drill bit if it's a really weird size. You can also get refill kits that just have the coil inserts in them. Most parts houses carry the kits in one brand or the other.

 

If something like a Keensert doesn't work, sometimes you gotta pony-up and spend the $175. You can hate it, but at least you're moving on. It only hurts for a while. I have several of these scars in my vast and esteemed portfolio.....

 

Kinda like the flags on the side of a WWII airplane, lol.

 

thanks.. I don't usually visit NAPA stores , only one here in north Austin and I never did like the layout or attitude.. but having some helicoils around would be a good thing..

sam