Major problem with oil drain bolt

[river_bouy]

Hi,
I have an '84 suzuki DT50.

During changing the gearcase oil, I have managed to strip the thread of the bottom drain plug (the thread in the hole not on the bolt itself).

Only the first few threads are stripped and then there is a good amount of good thread deeper in. Problem is, the bolt is only real short and does not reach the good thread deeper in. I can get the bolt to hold without the rubber washer seal, but as soon as I add the seal the bolt is not long enough to reach the good thread.

I have tried re-tapping the thread but it is too far gone.

I purchased a longer bolt that screws in find but it is not made of the same metal as the original part (original is aluminium I believe). The bolt I have purchased is just steel that I have sprayed with galvanizing zinc.

My question is, do you think this will be okay? I can hunt around for a stainless steel bolt but would this still cause corrosion issues (two different metals)?

Are there any other options?

Such a small issue but my boat is unusable until I come up with a fix.

Thanks heaps in advance.

 

[BaileysBoat]

Re: Major problem with oil drain bolt

Steel might be worse than stainless, but if you coat with some pipe sealant to insulate the bolt from the housing you should be ok. Are you in salt water? The main thing is to get a good seal, and check the bolt for corrosion after 50hours or so.
Good luck.

 

[James R]

Re: Major problem with oil drain bolt

If you dont want potential problems down the road either helicoil or get a stainless bolt.

 

[river_bouy]

Re: Major problem with oil drain bolt

Thanks for the help guys.

I will put in a stainless steel bolt as a temporary fix until I can get a proper mechanic to helicoil the hole.

 

[river_bouy]

Re: Major problem with oil drain bolt

.....and yes, the boat is in salt water the whole time.