Getting in deep

[SuperXRAY]

1983 944 N/A - Head Gasket Job.

Ok, so I've been taking my time on this job, doing it right. I have all the gaskets and materials needed...but while I was working on cleaning up the sealing surfaces on the disassembled head today, I went to blow everything out.

I had to drill two of the exhaust manifold studs, where a previous owner had work done and did NOT use Porsche originals or equivelants, as they were not Grade 8.8. However, I managed to drill them out and retap them, but noticed when I originally took everything off the car that previous work was done involving slotting a hole on the #4 cylinder exhaust manifold port. I thought this was odd, but didn't pay much attention to it. Well, the previous mechanic had to do a repair to a stuck stud on that port, but instead of drilling the stud out, they chose to drill BESIDE it (which is why the manifold hole was slotted).

History: The car had an extremely small coolant usage, probably a quart every couple months, but there was no indication of any leaks.

Now I know why. The previous mechanic drilled the hole so far into the head that it broke through into the coolant passage. When I blow air into the stud hole, you can feel it coming out of the coolant passage directly adjacent to it.

To my taste, I would prefer a newish head that hasn't been jacked with, but I believe it is possible to fill the hole with a steel epoxy, drill the original stud, then retap it. Has anyone had this successfully done before? I despise work like has been previously done on the car, especially given who did it. However, I know the car is farily worthless sitting in the garage not running.

The GF is fed up with having to repair the car, because it was supposedly in 'excellent' condition when she bought it nearly four years ago. It needed brakes then, then soon after the water pump went, then soon after the head gasket and oil cooler seals. It still needs the head repaired, a rear hatch seal, and rear drive shafts because of the slop. What would YOU do?

[Vicious]

with the amount of heat the head see's i wouldnt even attempt using the steel epoxy or putty crap. one of the members on here has refinished heads for 250+ i would contact him and be worry free that your "epoxy" job doesnt come undone and make things worse.

IF you absolutely cant spend that much the next best thing to do would be to drill it out larger, tap it, screw in a grade 8.8-10 bolt grind of the tip and repeat the process drilling half way into each screw until you are back to the original bolt location.

[SuperXRAY]

That's where I was headed too. I have a hard time putting broken stuff on what is supposed to be a daily driver...