Ignition Switch, Help Help Help
 

Have the mechanical portion of the ignition switch out. Drilled and ground the shear bolts off and it dropped out OK. Problem: One of the shear bolts will not come out of the switch. The other one came out OK and it looks like someone used Locktite on it. I've tried everything (WD-40, PB Blaster, Heat...). I've even sent a drill down through the entire bolt and drilled it almost to the original threads in the housing. Looks like I may have to drill and tap now. Anyone know the screw thread size? Possibly I can send a tap down to knock out the remains of the bolt. http://forums.pelicanparts.com/uploa...1166193282.jpg

I would try installing a helicoil. Go to the http://www.mcmaster.com/
website type in helicoil and determine the size thread/coil/drill you will need and then buy from them.
You HAVE to buy their taps and tools otherwise the helicoil won't work. It might cost a few bucks but as you might already know the ignition switch is pretty pricey.
Find a drill press to drill a proper hole.
They deliver quickly. Hands down best hardware website anywhere.
You might find that when you are finished that the hole alignment might be off slightly.

I've got a better idea.
If the original thread was 6mm and you decide you want to go that route I'll send you my helicoil tool, tap and a few helicoils. Send me a PM with your address.

Mike, thanks for the help..... It backed out with a helicoil. You're the man!