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[Oudaios]

Whilst fitting the Hitchcock pressure relief valve tappet cover modification, I have inadvertently done the unthinkable. Despite my best efforts, I have managed to strip the thread in the engine into which plugs the base of the oil feed pipe.

Any suggestions as to what to do next would be gratefully received. Please tell me this isn't an engine out job!

[Norm]

Electric start or non electric start?

[Oudaios]

Sorry, should have said. It's a 94 kick start 500

[PeteF]

Once that thread is in place it shouldn't have to move again so, unless you have completely stripped out all the thread, epoxy might be the way. If not, I think you'd have to remove the barrel to get enough access to helicoil it.
Either way, you will have a problem with swarf getting into the oilway.

[Dennis C]

Use a Helicoil, fill the hole with grease before drilling and again before tapping this will hold all the swarf and make it easy to remove without it getting into the oilway.

[apparently lucky eddie]

Epoxy products such as araldite will give way once they are in contact with oil so do it properly and helicoil.

[PeteF]

I wasn't suggesting Araldite but Loctite make some specific epoxies for the job.

[Alan R]

Hi guys--------- As per DENNIS C plus plenty of clean clothes etc... Seriously though, if you're non-to happy about helicoiling ie}--- first time,maybe ?? then don't be afraid to get a professional to do it for you..... This isn't the best of places to start a learning curve on....

[PeteF]

Seems I'm out-voted on this one Oudaios.
Who suggested epoxy?? Terrible bodge!!

They're right of course, you should do it properly. but the barrel will have to come off as you only have 3" above the hole without the fins getting in the way. Not enough to get any normal drill in straight.

[Norm]

I would also consider having the motor upside down so the swarfe will fall back out as you cut the thread, but the swarfe may not cause a huge problem because it can only be pumped up into the rockers and get stuck there. If whitemetal won't go through the rockers neither will a bit of swarfe