I'm almost afraid/embarassed to post but here's the result of getting the EZ out removed.
Argh! Not what I planned but one of those things I kept getting deeper and deeper into it.
I'd really prefer not to remove the engine. What reasonable options do I have to fix this in place? A few I can think of are...
- metal epoxy (devcon I think it's called) to fill, drill out again, insert Big-sert (oversized timesert) -
http://www.timesert.com/
- getting mobile welding service to come out and see what he can do
- get it towed somewhere and see what they can do
- ummm... remove engine and bring to machine shop?
I don't need perfect. I need to get this engine running and using the car for not too much cost. Is there an iron weld stick that can be used to fill oversized hole?
Also, looking at some of the other head bolt areas, is this an insert/helicoil? Or is this normal?
Maybe this is why when I tried to torque a head bolt it broke off. Maybe the bolt bottomed out in the helicoil?