Stripped out header bolt hole on alluminum head, how can I fix this?

[BlueOvalStangGT]

About a month ago I blew a header gasket and upon replacing the gasket, I had some trouble with one bolt hole. If I used a stock header bolt it would work ok, but if I used my Mr.Gasket bolts it had some trouble gripping until the end. Well yesterday when I blew my other header gasket (dont ever get paper ones) I noticed the bolt which I had trouble getting in, had fallen out. Is there a sleeve of some sort I can tap in there to create a new bolt hole, or do I need to drill it out and use a larger bolt? Hopefully the first.

 

[nmcgrawj]

I think the biggest problem is gonna be fixing it on the car. Your first option i think you are referring to a heli-coil. That still requires drilling if i recall but im not positive. Or you could drill and re-tap a bigger size but im not sure how that would intefer with the headers.

The cheapest and easiest option for you to try could just be a thread chaser. I had fudged up a spark plug hole and the chaser put the threads back into good condition. The thread chaser cant make it worse, but if the bolt isnt catching threads but still goes in...i'd be afraid to say that it seems the hole is already too big. But its worth a try.

 

[zenboy99]

I had a valve cover bolt get stuck in my TW head this summer. I had to take it to a local machine shop so they could drill it out.

The machine shop told me that the valve cover bolt hole wasn't drilled straight. They checked my other bolt holes and said they weren't very impressed with the machining. Maybe this is a Trick Flow problem?

 

[RIO5.0]

Well that blows... If it was me I would hunt for a bolt of slightly larger diameter and try to thread that in...Thats saying its a quick fix and could get you by...you may or may not be able to send it all the way home so I would try it and see how it feels...if it felt as though it would thread, I would go in far enough to get some bite enough to hold it...that may mean stacking some washers on the bolt....

As mcgraw mentioned a heli-coil is the right fix....hard tellin, the hole could be stripped to the size a heli would fit??

Alum threads suck...Good luck...and remember to anti-seize..

 

[VibrantRedGT]

I'd retap and use a bigger bolt. If it were off the car then I would do it right.

 

[S/CBlack95GT]

Get some Fel-Pro 1415 header gaskets and you will never have a problem again. If you have a solid flange headers you may be able to get away with not using that bolt hole.

 

[BlueOvalStangGT]

Where can I get these helicoils? Its actually in a spot that is real easy to get to, so if little drilling is required, it may be feasable(sp??)Im going to try re-tapping it, then a larger bolt, then a heli coil.

Get some Fel-Pro 1415 header gaskets and you will never have a problem again. If you have a solid flange headers you may be able to get away with not using that bolt hole.

I dont see how washers or header gaskets would help? Or are you refering to blown header gaskets? Wouldnt I possibly want a slighty longer bolt then shorter? My headers dont have a one piece flange.

 

[urban96]

I'd retap and use a bigger bolt. If it were off the car then I would do it right.

+1

 

[Rootus]

Where can I get these helicoils? Its actually in a spot that is real easy to get to, so if little drilling is required, it may be feasable(sp??)Im going to try re-tapping it, then a larger bolt, then a heli coil.

Helicoiling it involves drilling it perfectly straight to a known diameter, tapping it, and screwing in the helicoil. You really need excellent access to do a good job IMO. You can get helicoil kits at Napa. It's been a while since I bought one, but I remember they were spendy.

I dont see how washers or header gaskets would help? Or are you refering to blown header gaskets? Wouldnt I possibly want a slighty longer bolt then shorter? My headers dont have a one piece flange.

Just get gaskets that won't blow . Fel Pro 1415's are the only ones that have ever worked perfectly for me. I've tried copper, dead soft aluminum, paper (came with the BBK LT's), and the 1415's. The 1415's, hands down, are the best gasket I've ever used. And they're steel cored, so they won't come apart if you do have to remove them, and they won't stick to the heads or headers.

Good luck.

Dave

 

[drakesdad]

That happened with my Trickflow head as well. We tapped in and rethreaded it with a larger bolt. NO problems since. I have all 3/8 bolts except for 1 7/8. LOL it runs the same....

 

[95cobraguy]

like others have said i would try running a tap into the hole a few times, then try to get a bolt started. i wouldn't even thing about doing a helicoil yet before the tap method. and like rootus said, having excellent access is a must to really do the helicoil properly. good luck man, it sounds like a ****.