I had almost the exact same issue with one of my tranny mounting stud holes which had a very sketchy helicoil repair and a broken stud in the bottom.
I just drilled it out, I don't mess with easy outs.
I have a bunch of 10mm VW case savers that have an odd coarse standard outer thread at 1/2"-13.
Most well stocked aircooled VW shops would have this case saver..

Note the homemade insert driver, also I didn't have a tap, so I got one from China, $10 delivered to my door, but at the time I wasn't in a rush.
I think this is a good solution and I'm confident hanging my build from it.


http://www.914world.com/bbs2/uploads...1394543952.jpg
http://www.914world.com/bbs2/uploads...1394543975.jpg
http://www.914world.com/bbs2/uploads...1394543997.jpg

Was not able to get to the stud again with wedding trips and what not. I did manage to do a nice run through he N. Cascade Loop this last weekend! I was always planning to close out the Summer on that drive with my 78.. but here we are.

Im gong to drill it out and use a time-sert. Anyone have an idea of how long the insert should be 10x.15 x 30mm or 40mm in length? I'm not sure the length of the original stud, but there is enough room for a 40mm insert. Any negatives in that route?

I will use the carrier itself as a guide, if I can get a bit long enough for it. Im obviously a bit nervous to have this start to get off-center. :|

I would just take it to a good machine shop. They have a few different ways to handle the problem. You have some very reputable P car shops in your neck of the woods. Hand tools will no longer get it straight IMO, well without a great deal of luck.

I have spent hours on crud like this over the years, only to end in more frustration, spending more it tools that a sano repair would have cost from a pro.

Kinda sux you are finding the issue after the heads are on, send them a pic and ask if they can handle if you don't pull it all apart. The motor is not all that heavy and may still be able to be set up on a lathe table, shimmed for square , etc.

sorry for the late response, but I took it to a shop and got it replaced. :)

http://forums.pelicanparts.com/uploa...1490736482.jpg

Looks like a Time Sert installed with blue loctite. If it's installed well now it's stronger than it was originally.

If you ever break off a drill bit or easy out in something expensive you can drill them out with a Cobalt drill bit. Snap On has them and hopefully they are available from other places too. They are amazing drill bits and will drill through any metal I know of.