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Yeah Mark, you're right. I should've filed it down first. I did punch it myself, and it seemed pretty centered, but I guess not. Helicoil is probably the best way to go now, although I am nervous about going all the way through with it. Having 9 out 16mm of the original hole should be safe and is a lot less scary than drilling completely through the case and possibly dropping metal chunks in.
I did try the screwdriver trick, BTW, no dice.
Real question to me: WTF happened to the original bolt? I checked the torque wrench against another one that has a indicator instead of a click (by pulling and redriving a random bolt in a metal door frame), and it was true to within 1 ft-lb at 8ft-lb's. So the bolt that pelican shipped me snapped with less than 8 ft-lb's??? That's crazy. I must be cursed on this job.
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"Betty" -- 2000 Boxster S, Triple Black, loaded except PSM (sold to a good home)
"Veronica" -- 2008 Boxster S, Arctic Silver on Blue
"Maleficent" -- 2007 Cayman S, Red and Black, TPC Turbo 3.6L 460 RWHP, H&R RSS Coilover / TPC stage 2 suspension
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Threaded Mode
