Re-retapping Manifold on 49' Champion

[aj86]

Some of you may know the story of our Champion my father in law left my wife in febuary after his passing and I spent six months resurrecting something that had set for 30 years. Well I had to hurry on a few things to get it ready by the wedding date. One which I have to redo again. I had to retap and die four holes on the manifold of which where the original bolt broke off in, I wanted to reuse the original part. Well one of the holes on the exhaust end I miss tapped by about 3/32" off center so it just enough to not get a bolt in there so it has a slight exhaust leak when it runs at higher rpms. Anyone have experience or advice how to fill that hole in and re-retap it again? Thanks

[TDITS]

If it's only off by 3/32 it's not off by much. I would think it would be a lot easier to egg shape the hole in the exhaust manifold to get a bolt to start in your existing bolt hole.

[Lark Parker]

Yeah, that sounds like a job for the rat tail file.
You probably don't use it that much anyway.

[thunderations]

If you can carefully grind that hole back towards center and then redrill and tap it for a helicoil, that might work.

[aj86]

I thought of just drilling out the flang on the exhaust pipe but the hole is off center toward the exhaust outlet so i wouldn't be able to get a bolt started on there because the head of the bolt would hit the pipe when trying to start the threads

[DieselJim]

Screw a bolt in the hole. Cut it off flush. Center punch and drill a new hole then tap.

[jimmijim8]

grind a bit from the exhaust pipe to clear the bolt head meybe. cheers jimmijim. I like the other idea.

[Chipmaker]

use a socket head bolt(allen wrench type)