In the process of trying to drill out the shank of a broken off water cover head bolt in the cylinder heads (Yes, I managed to it on each of them! At least I'm consistent)I broke off about a third of the wall of a blind hole that takes the 1/4" bolt thread. <br /><br />I need to build up a false wall that will hold to the rest and take about 5 ft lb torque.<br /><br />I fixed up a couple of other damaged holes by cold welding studs into them and they'll hold torque, but the ones I'm asking about don't grip and won't take more than a few inch pounds.<br /><br />JB, epoxy steel (the sausage type you cut a bit off and roll in your fingers), Loctite thread repair and few other things haven't worked.<br /><br />Alloy welding costs as much as a second hand head and it may not work in view of the age / corrosion factor of the alloy, so it's not an option as I have to pay for it. I've got a little MIG welder but nothing that'll weld alloy, not that I'd be able to anyway.<br /><br />I don't have gas welding.<br /><br />I do have arc and once I'm satisfied nothing else is going to work and the head is a write-off I'm going to tap a coarse thread into the hole and melt some arc into it and see whether I get something that can be retapped to the right size. <br /><br />Before I do that, is there anything else I should try?
