Thought I'd share this video I found for anyone else that might be a bit ignorant of this topic like myself -

Thread Insert Deathmatch! Helicoil vs TimeSert vs key locking insert vs BigSert

 

Caution: Aluminum melts at about 1200 degrees, steel at 2400, cutting torch temperature is about 7000 degrees with the oxygen - do this wrong and you wind up with a very big hole in the head. I would recommend removing the head and taking it to a machine shop.

 

Thanks for all the help.

I have got the stud out the drill wondered and made the hole bigger and may of hit the water jacket. but I got it out.
I am thinking about doing the helicoil as time serts are £150 plus there do look a lot better option if it was cheaper
.

I have also been thinking about trying some Quicksteel instead mix it up pack it into the hole and then drill and tap it as it says it can be tapped and is good up to 250C
has anyone used it before ?

 

i used a quicksteel-like substance to repair a reinforcing webbing inside a motorcycle engine once. it was relatively low load and was not directly adjacent to the combustion chamber but it worked just fine. i would not have tried tapping into it -- it really didn't feel like the thread would have been reliable.

 

I would mic the hole, buy a stud that's going to fit the hole, run a tap and make new threads, drill out the manifold so the manifold fits over the new stud.

If that fails, I'd buy a junkyard head for about $40, clean it up, check the head surface and reassemble.