I am still on this project of installing the tensioner bolt. So far everything
has failed to attach it. Only choice left is to drill further into the engine, and
try to make some new threads.
Anyone have an idea how far you can drill into the engine, and not damage it structurally ? Attached is the photo. Can you drill 1/4", even 1/2", or more ? If I can drill through the material with cobalt bits, I am going to drill 1/2" in.
Note I also tried JB weld and Quicksteel. They fail as they are no good under tension.
if you aready have hole drilled, you can find a thread tap and a new bolt to match the new treads. buy a strong adhesive to use on the new bolt, I've had good experiences with locktite products. Get a hold of the Locktite Epoxy Weld compound. You should have a hard time getting the tensioner off again with that adhesive
None of the weld type products hold up under much or any tension. And there is a lot of side tension on the bolt when the timing belt is moving.
I don't know why I am having a difficult time drilling the whole deep enough to hold the bolt. The material is very hard after you get about 5/8" deep. That is not deep enough for this problem as the beginning part of the hole got damaged and widened when the bolt broke off. I have to drill deeper.
I got a different tensioner bolt that has much longer threads. If I can drill deeper without damaging the engine, this can still work.