Well something as simple as changing a thermo which I have done many times took a turn for the worse today when the bolt broke off in the intake.

1. Started drilling out bolt. Took forever. I now have a hole that is somewhere between 3/8 and 1/2. Don't ask.

2. Very worried about drill shavings getting into engine.

3. Started to tap new threads-NEVER DONE THIS BEFORE, and can't really get them right. I am prepared to go bigger like to 1.2 but is this a mistake? Right now I don't have good threads.

4. Is there an alternative short of a new intake.

5. Hoping I don't have to do any drilling on the housing as this would probably be a nightmare too.

6. And all of this before I get to the real problem. Why is my fan not coming on?

Help me if you can before I screw(nice choice of words) this whole thing up. I just want my car to run at operating temp.

 

I would have responded sooner, but I've spent the last three days reading your signature...

If the hole you drilled is still in the correct location, and hasn't tailed off to one side, you should be able to install a thread insert and new bolt. If your drilled hole is already over 5/16", there is no tapping the hole for a new 3/8-16 bolt.

you may need to tap 5/8-11 and install one of these:

 

Sorry about the sig, it just has grown over the years.

Where can I find those inserts? They seem like a plan.

 

You should be able to find them at any parts store. Any place that sell Heli-Coil stuff will have them.

As far as your fan, have you checked the motor?