,

[rex]

Thanks

[varg]

If you have a decently large compressor: http://www.harborfreight.com/3-8-eig...ill-67474.html

[Kershaw]

Does the old bolt still thread in? Maybe RTV it in place?

[Matt-B]

id drill and retap

[rex]

If you have a decently large compressor: http://www.harborfreight.com/3-8-eig...ill-67474.html

An angle drill could work. Seems like it would still be pretty hard to drill straigh and square inside the engine bay

[rex]

Does the old bolt still thread in? Maybe RTV it in place?

Most I can get it to go is about 1.5 threads worth. Turning past that pops it out. I thought about RTV but i dunno if it would hold up to the pressure since it's not even close to fully in there.

[rex]

id drill and retap

I agree this is the eventual necessary solution, just wondering if I can do it properly without pulling the motor.

[rex]

Another idea I had was to fill the hole using JB weld putty, thinking that I was going to have to re-drill the hole anyway later on. Bad idea?

[Seawolf]

You could try some copper wire, insert 6 strands of copper wire into the hole (this will be tricky with the plugs location) and wind the plug in without the sealing washer. The hole may just have enough thread to grip the soft copper.

If this holds well enough unscrew the plug, snip the copper wire ends with a pair of good side cutters fit the sealing washer, apply thread sealant to the plug and wrench it down.

You will be able to apply more heave than you think to this and it has worked well on a few stripped ally threads in the past where overdrilling wasn't an option. Use a medium gauge single strand wire.

[Old525i]

Remove cat. Plenty of space will open up.

[Kershaw]

Most I can get it to go is about 1.5 threads worth. Turning past that pops it out. I thought about RTV but i dunno if it would hold up to the pressure since it's not even close to fully in there.

If you can't thread the bolt in, there is metal to tap. I'd try to retap it with an actual tap, not a thread restore. Then thread restore the bolt. Check to see if it goes in. Then Teflon tape the bolt and put it in.

Sent from my SGH-M919 using Tapatalk

[packratbimmer]

Drill and use expanding rubber plug. Make sure to flush metal shavings

[rex]

If you can't thread the bolt in, there is metal to tap. I'd try to retap it with an actual tap, not a thread restore. Then thread restore the bolt. Check to see if it goes in. Then Teflon tape the bolt and put it in.

Sent from my SGH-M919 using Tapatalk

I used an actual tap, or at least the only thing I know of as a tap, looked like this except it was the right size-pitch. It seemed to work fine.



The tap also pops back out when I go past a certain point, just like the bolt did

[rex]

Drill and use expanding rubber plug. Make sure to flush metal shavings

Some guys on the r3v Facebook group suggested an expanding rubber plug and I have ordered one (no local stores had em and I went everywhere looking lol) and will give it a shot.

[rex]

Remove cat. Plenty of space will open up.

Cool, great to hear