I just drained the oil to work on the clutch and noticed that the fastener was different in that location than the other two.
It seems that a PO had trouble with that stud and drilled and tapped it for 1/4-32. The fastener in that location was a 1/4-32 bolt with a lot of washers as spacers.
My original plan was to install a 6X1mm helicoil. The drill size for that is 1/4 inch. I removed the exhaust, made jig so that I was sure that I was drilling straight and drilled it out to 1/4 this afternoon. I used a new bit and used grease to help get a nice new cut. It seemed like the drilling process was a bit too easy. After drilling, I still see a faint outline of the threads that the PO cut.
So, I am at a crossroads. I think that I could continue with the helicoil install and be ok, I think the tap it much larger than the remains of the damaged threads. But, I want to make sure that I am not making a huge mistake before I continue.
I looked at switching to Time Sert, but the drill for that is a size D drill bit (0.246 inches). I have already drilled to 1/4.
The next step up would be the Big Sert. The drill for that is an L bit, 0.290 inches. It looks like that drill size would take me into the o-ring.
So, I think that the only options at this point are to continue with the helicoil or Time Sert. For the helicoil option I am considering installing the helicoil with red loctite to strengthen the helicoil engagement. Or, maybe I am over-thinking of this. Can I get some opinions of some of you that are machinists or have done a lot of thread repairs?
Thanks,
Andy
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