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I’m trying to help a friend out; maybe the experts here have an easy solution to this problem.
Some shade tree mechanic, that is, if I could call him a mechanic, used metric bolts to bolt the gas pump on my friend’s 292. Now, the threads of the front cover are gone. I thought about getting the threads done again, and use a larger bolt, but then, the larger bolt's head won’t clear the gas pump. Is there a solution to this problem, without having to take the front cover off? Any ideas would be greatly appreciated.
You could try using a helicoil or some similar thread repair system but I'm not so sure that will work. I don't think there is enough material in the front cover for it to bottom out. It may just unscrew as you torque the pump down and that could cause it to strip the new threads or fall out in the engine. You could also have a sleeve made with the propper thread, 3/8 - 18 I think, that is press-fitted into the cover. You could also have a machine shop make a stud that is oversize to screw into the cover and 3/8 for the pump and just use nuts to tighten it. You should remove the cover to do the work because you will have to drill out the holes and you don't want to contaminate the oil. I think, however, that your best option is to find another cover.
Thank you very much for the reply. I have to agree with you, a new cover is the best solution…
But, as I’m going to be the one helping him out to fix this, I was wondering if there would be any other practical solution.
I’ll just go ahead and tell him to change the cover out. Luckily I have a good front cover, ready to be used.