With five studs left, I played eeny, meeny, miny, moe and picked one. Same routine as yesterday, center punch, drill, drill, grind with Dremel, and tap. Finished the hole, and the threads looked a tad too shiny. Ran a stud into the hole and sure enough, it was sitting at a slight angle. Looked real good down the hole and could see at the bottom where there was stud material, then block threads outside and below that. Used my custom chisel and found indeed there was stud material on one side of the hole. I guess the remaining stud material was still too thick in this area, and the tap dug into the opposite side of the hole into the softer cast iron. Drat! Cleaned the hole back out and ran the stud in to the band. It is sitting straight in the hole now, but is wiggly if you back it off that band.Looked into all my other holes, and found another one that was identical. Double drat! Cleaned that one out as well. I guess I need to ensure the stud material is thinner at the bottom than I have been. So now my questions - if the stud is wiggly in the block (just a tad), but snuggs up when you screw it into the block all the way to the band - should this hold alright? Also, would extra sealant be needed to seal the stud threads up against coolant leakage or still the same anount towards the top most threads? Any action I should consider taking with this issue? TIA,
Dan
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