Tired and frustrated with the glycol in oil leak..

[Excaliber]

That was basically my point Undy, I suspect you WOULD have used them had they advised you to, talked about the issues and such. It just seems like the alloy block companies are doing a dis-service to their customers by not discussing this critical issue.

[scottj]

I had the same thing happen on my first aluminum block. I was not aware that the block used a special stud with 1.75" of thread that bottoms in the hole. The standard stud pulled a chunk of the block out between cylinders. I used the argument that since they included a list of required special components with the block, the studs should have been listed. The Chevrolet Racing dept ended up raplacing the block.

[undy]

Yep, it's the old hind sight thing on the head studs...

I did have a lengthy conversation with Barry this AM. I know it's been said before, he's a great guy with tons of knowledge that has a passion to help fellow FEers... Kudos to you sir!!

It seems that the Pond block's head bolt holes are not heli-coiled, just raw aluminum and are threaded 2" deep (as I'd measured). Barry suggests NOT USING a time/big-sert as the intention of the head studs are to grab the block as deep in the casting as possible. He likes Heli-Coils. The time/big-sert will only grab a max of 1" deep and that's at the top of the hole. Heli-coil does makes a 1/2"-13 insert that's 1 1/2" long that I can bury at the bottom of the existing 2" theaded hole. Since it's not had an insert already I can use a standard diameter heli-coil. I'm starting to get a warm fuzzy about the repair.

The head gaskets... Barry doesn't like the Cometic MLS gaskets for one reason. Cometic fails to install an embossed water passage sealing ring around their head gasket's water ports. The FEs being somewhat unique WRT their oil passages near the water passages this become very important. With his advice I'm tending to lean towards the Felpro 1020s..

BTW... YOU GUYS ROCK! Thanks to all for the wonderful support and advice that was given. It was always considered and sometimes followed More to follow....

Dave