4 hours ago, Captain Obvious said:

That chunk of brass was some sort of plug he stuffed down into there to seal the bottom of the hole back up.

So now I'm going to spend the next bunch of hours working on trying to fix that crap.      

Don't confuse from with function.  If it doesn't leak then, technically, it's fixed.  If you can get the hole properly aligned and threaded so a valve cover bolt works correctly, then, technically, the problems are solved.  You could be heading down a worm hole trying to fix something that is only aesthetic.

 I'd be tempted to try one of the liquid or putty epoxy thread repair kits on a low torque bolt (or stud) like the valve cover bolts. Loctite, Permatex, JB Weld all have something to offer. 

1 hour ago, Zed Head said:

Don't confuse from with function.  If it doesn't leak then, technically, it's fixed.  If you can get the hole properly aligned and threaded so a valve cover bolt works correctly, then, technically, the problems are solved.  You could be heading down a worm hole trying to fix something that is only aesthetic.

You're forgetting...CO has a touch of OCD. 

You're forgetting...CO has a touch of OCD. 

Just a tiny tiny bit, but so do I.


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This forum is very therapeutic.

I got a couple hours in the shop today. Here's what I started with. You can't really tell from this pic but that hole goes in on somewhat of an angle. It's not square to the top surface. It cuts in towards the center of the head:

First I bored out the hole (hopefully close to the correct location) to about as large as I was comfortable with. Here you can clearly see the off-center hole that punctured down into the water jacket below:

Then once that was done, I threaded that hole:

And made a threaded insert on the lathe:

Here's a test fit:

I didn't glue the insert in yet. I'll do that tomorrow with a clear head. And then after I glue it in, I'll cut off the excess and machine flat.

 

Edited July 13, 20195 yr by Captain Obvious

So I know that I'm way past the point of reasonable cost-benefit-labor-hassle...

But at this point, it's me vs. my PO.  It's personal.  

Oh, and my donor cam from @jonathanrussell arrived today and looks great!

Thanks again for the incredible generosity!!   

I got a couple hours in the shop today. Here's what I started with. You can't really tell from this pic but that hole goes in on somewhat of an angle. It's not square to the top surface. It cuts in towards the center of the head:

First I bored out the hole (hopefully close to the correct location) to about as large as I was comfortable with. Here you can clearly see the off-center hole that punctured down into the water jacket below:

Then once that was done, I threaded that hole:

And made a threaded insert on the lathe:

Here's a test fit:

I didn't glue the insert in yet. I'll do that tomorrow with a clear head. And then after I glue it in, I'll cut off the excess and machine flat.
 

CO, I’m impressed. Nice work. Regarding the ”labor-cost-benefit”, I’d say this is a labor of love. Minds like yours and many on here need these mental and skill challenges. So try and enjoy what it a know afterwards that you’ll sleep well knowing you did it right. The PO didn’t have the luxury.


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Oh, and my donor cam from [mention=7021]jonathanrussell[/mention] arrived today and looks great!
Thanks again for the incredible generosity!!   

One of the many great things about this Forum. Most people on here regularly, are on because they love these cars and the camaraderie with the members, not to make a buck or boast and prove their expertise. The pay it forward mentality for the greater good of the members and forum is the prevailing culture.
Jonathonrussell just proved that once again![emoji481]


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I knew the swarf maker would come up with an elegant solution!

Awesome skill and creativity.