stripped hole for t-piece coolant system

[micbrody]

I went to flush coolant today. Everything uneventful. I had trouble burping system and saw that directions recommend removing bolt from t-piece to get air out while filling. When I tried to loosen, the whole assembly slightly moved, and the gasket started to leak. I tightened the upper bolt without issues; the lower bolt would turn but not tighten. I removed bolt and saw bolt was stripped. at last 3/4 of a centimeter. I replaced bolt , but same thing happened. The cast hole must be "screwed" up. What are my options? I tried to show some copper filament down while tightening; no luck. I used a similar size sae bolt; no luck. I think I need to pull the whole assembly and re-tap the female holes......which means I have to drain the system; find a die, etc...... Is there a better way without removing assembly?

[azruss]

first, try a longer bolt and see if you still have a few good threads at the bottom of the hole. After that, you are looking at a heli-coil. I doubt if you have the room to do the heli-coil without removing the T

[micbrody]

I tried longer bolt . No luck

[micbrody]

I took t-piece off. The receiving hole had been helicoiled; but it failed. I pulled out mangled helicoil. now the next step:Not sure how to proceed:
1: try to put new helicoil in hole. Not sure I want to do that since it failed; maybe PO had not installed helicoil correctly.
or
2: pull entire receiving unit; tap a bigger screw hole
or
3: find a receiver unit for t-piece(still not sure what it's called)

What a pain in the ass. I guess this is what owning an old car is all about.

[ORFORD2004]

Fill the hole with a tig welder and retap

[micbrody]

What's a tig welder? How much does it cost at harbor freight ?

[Ramzi]

.....What a pain in the ass. I guess this is what owning an old car is all about.

Thats a whole lot less than this


http://www.autoricambi.us/product/CO0-0 ... --1980-on/

[azruss]

if the heli-coil threads are shot, then you need to go up to the next size. You could try JB weld and re-tap. You would need to be careful how tight the bolt is. You would also have to prep the existing hole to provide plenty of grip for the epoxy.

[vandor]

I think you have nothing to lose by reinstalling a heli coil and see if it holds. I think there is not much material there, so I am not sure if it can go much bigger. BTW, I called it the water outlet.

[ORFORD2004]

What's a tig welder?

Find a guy who can weld it with a Tig

[micbrody]

I was able to cut about a third of a nut off to fit behind hole. I packed hole with epoxy weld. Threaded a screw into it and engaged the nut. Lightly tightened (I put tiny washer in gap between nut and back of hole to keep nut from torquing in misalignment as I tightened. I then covered the entire bolt and back of hole with the epoxy.
After 12 hours, I made sure I could lightly loosen bolt. I then waited another 12 hours and success.

[micbrody]

I would post photo; not sure how