Because of the relatively large size of the drill hole and that fact
that you probably don't have access to a jig that will make a perfect
right angle hole (you need a thing called a do-all, haven't seen one in
years) I think you are taking a big chance on something you can't
afford to make a mistake on. Have a machine shop/performance shop do
it, plug the hole with gas tank leak stop (it's available at your
FLAPS, comes in a long stick and you knead it to activate it) to drive
down there, or have it towed.

You could make your own jig by drilling a hole through a thick piece of
metal and welding that to a strap and bolting that to the block
somehow, but you're still taking a big chance.

Jim

On Jul 20, 2005, at 9:29 PM, Barry Muller wrote:

> Hello,
>
> I have a newer rebuilt 2.1l wasserboxer that while
> doing an oil change about 2 years ago I passed a
> brain stone and torqued the bolt instead of losening
> it.  Bits of helicoil came out that time and during
> every oil change since.  I was able to gingerly
> install the plug since and got a good seal, until last
> week (about 1,000 miles since the last oil change),
> now it leaks so bad I can not use the car.  Yes,
> painful, but of course I can only blame myself.
>
>
> Any rate, I've been told that to replace the helicoil
> with the next size up is the way to go.  I'm nervous
> about doing this because:
>
> A) Never installed a heli-coil before
> B) I'm concerned bout drilling the case by hand and
> having to keep a hand drill square to the case so I
> don't get a cock-eyed hole
> C) Concerned about drilling too deep!
> D) How do I keep the drill chips from getting into the
> engine and slowly machining my newish powerplant
> apart?
>
> I'm looking for some real-life experience from those
> out there who have gone this route.  I'd like to know
> how people solved the issues I listed above and how
> long the fix worked for them.
>
> I'f you've used another solution to this problem, that
> worked, please let me know about that too.  (No, I'm
> not going to use an old spark plug.)
>
> (At this point I think it'd be easier and safer to
> install a "molly bolt" (perhaps you knlow these as dry
> wall hangers - the ones with the little spring loaded
> expanders that deploy after inserting into the hole).
> I'd then use a heat-resistant synthetic rubber gasket
> and a washer backer to seal the whole bit.)
>
> Thanks in advance
>
> Barry
>