oops...HELP ME!

[madquickyo]

Think you ever had a bad day when working on an engine?

I was assembling my motor the other day and I had an accident. See, when going over all the bolts and torquing them down, I broke one. I was my belt tensioner bolt and it broke in my block. No big deal, ill get an ez out and get it out. Well, I drilled a little hole in the bolt, put in the ez out, and it wouldnt work. It was to small, it started to bend.
Ok, go to a bigger size. So I drill the same hole bigger to fit a bigger ez out in it. Same with that ez out, started to bend so I had to go to a bigger size. I done this 2 more times till I couldnt fit any bigger ez out in the bolt. After finding out this wouldnt work, I decided to just drill the bolt out.....thats where I went wrong.
Aparently, 4g63s dont like a drillbit being that close to them. So while trying to drill out the bolt with a small bit at first, I umm....slip...and yep, thats right, hole in my cylinder wall.
This pisses me off...so I figure I cant hurt it anymore, I decide to just drill out the bolt the rest of the way and see if there is anything I can do to fix my mistake.
Finally after getting the bolt out. I look and can see straight into the cylinder. I figure its about 1/16 of an inch away from the bottom of the cylinder so I can still use the block. My piston skirt will barley scrape it and there is no pressure that far down, so ill be all good.
Well, while taping out the block, I think I found out something else the 4g63s dont like...and thats a bigger hole then what is already there. Yep, you guessed it...I broke the tap in the same damn hole that I just broke the bolt in AND drilled a hole through...
At this point im so pissed off I could have set a kitten on fire. I mean this was really bad. So I decide I cant hurt anything again, I start to try to get the tap out. After about 1.5 hours or so of hitting the damn thing with a center punch, all of it finally comes out.
Now, time to re-drill a bigger hole and then tap it again.
Luckily, to my surprise...I dont screw up this time!! WOOHOO! Im jumping all around. Now time to get a heli-coil and get shit straight. And well, needless to say it works now.

Now that I have told you that story, here is my question on why I just spent 10 mins typing all of that.
What would you guys do? Would you re-use the block or get a new one? The reason why im even thinking this is because, like I said in the story, the hole is about 1/16...if that high, above the end of the cylinder wall. It so far down where my piston skirt will barley touch it. There is no pressure down there as we all know...So what damage can be done if I reuse the block? If you look in my profile you will see I have an extensive ammount of mods on my car, this is why I need the help. What would you guys do? HELP!

 

[half-cocked]

As long as you didn't punch through an oil or water passage I would reuse it, even though a lot of people on here will say its junk. As long as its that far down in the cylinder I see no need for replacing it. After reading about an Evo 6.5 using a eclipse crank found in the dump bin and using used bearings and climbing pikes peak, I am a believer in not everything has to be perfect.

 

[TSIfreek]

I would use it without question. I dont think the water passages go that far down in the block for the cylinder wall cooling. I would lightly sand/polish the spot were the hole goes thew the block/clinder wall were the piston might touch it. Use WD40 and light wet sand paper just to get all the burs off. I would also use thread sealant on the bolt for the pulley and use lock tie red on the helicoil going into the block. Doesnt sound like a big deal just be glad you got that tap out!!!
Next time dont use a 1/2" impact on a bolt that only needs 20lbs of torque
Could have been alot worse