How screwd Am I !!!!!

[wlaroche]

My firewall at work would not let me see the picture, but I would probably try and get a Heli-coil in there. If the damage is worse than that, a machinist could cut away the bad part, press a plug in the cut hole to fill the space that they removed, and re-tap it back to original size. It would be pretty easy to do. You just need to take it off the bike.

[The Buddha]

Honestly that self tapping thread is a good idea, I'd have done the same thing, in fact I did ... In your case though I'd put a stud in there with thread losker, so you dont remove the thing @ the head, just remove the nut on that stud.
Cool.
Buddha.

[sledge]

Weld this! Drill that! Tap this, tap that!....I admire the optimism displayed but a little knowledge is a dangerous thing.

There is only one way to get an effective repair on this. Get the head off, get it to a good machine shop and let them examine it, they will then advise on what they consider is the best way to reclaim it, and lets face it they are the experts.......Any other method is a compromise and may well prove unreliable and any further attempts to `butcher` the stud remenant out will almost certainly cause futher damage and possibly render the head unrepairable.

I suggest when the repair has been carried out proffesionaly you use chrome plated studs/nuts instead of those  s***e socket-caps to hold the header-flange against the port.

[Sbag0024]

Thanks for the info BUddha, I used some RTV to fill in the chipped area (even though its actually not leaking) and I also filled in the hole I drilled with the same luquid gasket. I did not drill into the head or anything like that, I only drilled the bolt casing and where the old bolt used to be. I feel I am now safe and sound. I am thinking about getting a used head and make a winter project out of it. =)

And Sledge I think When I clean it this winter I will just take it to a shop to have it compleatly filled and drilled.

Ty again everyone. =)