Well I was installing my driver side SLP 1 3/4" header into my camaro this weekend. It was an extremly tight fit as my header was rubbing bad on the steering shaft. Anyway I thought I had everything lined up but I guess not. All the bolts went in fine except one at the port in the front of the engine. Since I am using a aluminum head I guess I didn't realize it was cross threaded until the bolt just wouldn't turn anymore without being bottomed out. Anyway the threads inside the head came out on my bolt, so now I need a little advise. Since its the port at the front of the motor I at least have more room to work with. Whats the best thing to do, try and retap the hole? The bolt wasn't going in straight so I'm not sure if that would work. Anyway I would really like to fix this without having to remove the head from the car if possible.

Thanks

 

Drill it out and purchase a heli-coil kit to replace the threads. Available at any parts store, it will be better than new.

 

there are several thread repair inserts that are cheaper then heli coils, but somewhat harder to find

 

Thanks for the replies, do you think I can do this with the head still installed in the car? Lucky for me its all the way at the front of the engine. Also you don't think I will have any problems since the bolt was going in crooked?

 

Heli-Coil it. There's no real sensible alternative besides a thread insert.

 

You'll have to use an angle drill or close-quarter drill. Be absolutely certain that the angle is correct. You can either use a spring coil insert or a solid insert. If you use the spring-coil type, get the longest one you can. You will need to use a special (non-standard thread) tap for the coiled insert, and will not be able to remove the insert easily if you ever have to. Of course, I've had these coiled inserts come out with the bolt in some cases, which really compicates disassembly, since the fastener will not come out from behind a close-tolerance clearance hole.

The insert type requires a larger hole, but uses a standard tap and can be removed if necessary. They can be a little harder to find, however. There are some times the larger diameter will not be appropriate where there is little extra base material - like around some larger exhaust ports.

 

thats what I did when I broke an alternator bolt in my head. Right angle drill (just get a stick or steel and grind it out to a fine point and grind an end to where u can nicely fit vice grips or a wrench) and right angle drill a little in the head (sort of like a countersink) and hammer the fine tip on your metal then turn the other end with grips/wrench, worked for me more then once.