Aluminum Head and Valve cover problem

I live like 40 minutes from you

I would pull the head, because it does sound stripped. Have them rethread it or helicoil the thread. Good Luck!

Agreed. you'll need to drill out the bolt hole and helicoil it.

I agree that the best approach is a proper repair to the existing threads. You might be able to do it with the head on the car; you might have to remove the head -- only you can answer that for you.

Since removing the head is a BUNCH of trouble for this relatively small problem here's a suggestion. If in fact the threads are stripped you might try using a sheet metal screw with a hex head that has threads that are just slightly larger than the hole in the head. A steel sheet metal screw with coarse threads should be able to 'grab' the aluminum and hold the valve cover down. There's not much to lose in trying - if it doesn't work, you still have to repair it anyway. If it does work, it's as simple as screwing a different bolt into that one hole. You want the fastener to be no longer than the existing one, and only slightly larger.

backfocus - Yeah, just join us any time...it is quite large We got to rambling...good luck.

Personally, I would not try to tap the head with a sheetmetal screw. The potential for messing up the hole even more is too large.

It may be better to clean the area real well with brake cleaner (using a rag/paper towel) then smear a big glob of silicone over the area. Besides the nasty glob of silicone will help motivate you to fix it right.

Good luck whatever you do.
jason