magik235
Still Alive
Use a left handed drill bit and it might pull the broken sender out as you drill.You're over complicating this. Theres a broken sender in there. Drill it slowly and pick the remains out and put a plug in the thing and be done![]()
Use a left handed drill bit and it might pull the broken sender out as you drill.You're over complicating this. Theres a broken sender in there. Drill it slowly and pick the remains out and put a plug in the thing and be done![]()
I don't think there is a heli coil for pipe plugs. At least it never crossed my mind to use one.

One thing no one seems to have picked up on so far.
That is a Pressure hole. Everything is going out. So, after you get through doing whatever you have to do, before you plug it, spin the engine over a couple of times.
That oil gusher you are trying to fix will work in your favor this time. Should wash any filings or pieces out.

drill it oversize...tap it 1/4 NPT stick a 1/4 x 1/8 pipe bushng in it and be done with it....
One thing no one seems to have picked up on so far.
That is a Pressure hole. Everything is going out. So, after you get through doing whatever you have to do, before you plug it, spin the engine over a couple of times.
That oil gusher you are trying to fix will work in your favor this time. Should wash any filings or pieces out.
And yeah, I would double or triple check to make sure nothing is broken off in there.
Getting the remains of something out is many times better than tapping the hole.
Plus, if you start tapping, and there is something in there, you are going to break through to the old threads and really have a mess.
If you can get to it so that you have room to maneuver, get a magnifying glass and a bright light and examine the area close in around the hole.
Look for a seam or a different type of metal. You might lightly hit it with a grinder. What ever might be broken off in there probably is not the exact same material as the block.
If you polish it up, it will look different and you may be able to see the seam.
Maybe hit it with some brake cleaner to get all the oil off. Especially look for a slight pattern in the hole.
If there is something in there, and it has been drilled out to the inside of the threads, then there is not enough for the easy out to get a grip on without cutting into the threads in the block.
So, then you take a sharp pick and pick out the old pieces.
As always, you have to fully define and understand the problem. Right now, you don't know enough about it.

That hole is 1/4" NPT from the factory, it's the oil galley behind the distributor that is 1/8" NPT.

Hole size is really close to 1/2 inch...So going to tap it tomorrow. Do I use a 1/2 inch tap?
Tap------------------ Drill Bit.
3/8-18 ( 3/8 NPT) 37/64
All i'm going to add here is that he's about to screw things up and were going to see his next post about him pulling the engine to start building another block to replace this one that HE screwed up by not listening to the advice given him here.
I mean... a guy who had to ask how to get the plastic headlight bezels out is about to work on a motor after ignoring all the advice given to him here. Stand by.