Told I need new head if I want to fix an exhaust leak

Ask them about a keensert. It's like a helicoil but much thicker. Instead of just spiraled threads.

 

I don't think you'd have much luck with epoxies. There's a lot of heat there.

There's the option of a heavier insert. A guy could always see what a machine shop could do. A good machine shop can do things you never thought were possible.

 

Before replacing the head..

I'd go the redneck Option, & drill It out again & put a Helicoil inside a Helicoil.

 

weld up the hole grind flush and tap a new thread
or put bigger helicoil in or drill out the hole and weld a stud in and die grind round it

 

Or drill it to tap to the next size course bolt. Use a starter tap and then a bottom end tap. Install a grade 5 bolt with threads longer than the hole. Measure and record hole depth. Lock tight the threads, don't flood the hole, and tighten it in the hole. Don't over do it, 25 or 30 ft lbs? Let it set, cut it off and grind it flush. Stake the bolt ( three or four center punches around it an 1/8th in. out but go easy ). Find correct center hole location and center punch it. Drill out using small to larger bits to size for tape. Put tape around the bit to mark depth. Want to be at least 1/4" shorter than bolt. Install a bolt in the sister hole for visual alignment and have a watcher. Can do it on the truck if cab is not in the way.

 

Please do not let anyone strike an arc, wire or stick to your cylinder head! Keen serts are # 1 option, a machine shop would be # 2, only in my experiance and humble opinion, yes, it is repairable without a head change, my 2 cents without seeing it. Good luck, take care.

 

drill it out acouple sizes bigger tap it run a big bolt in cut it off flush then re drill an tap your size in the middle of that

 

Exhaust reaches upwards of 1400 degrees in a engine working at it's max. At those temps the steel is red hot and glowing. Ain't no resin in the world that can deal with that.

If it costs just as much to have a machine shop rebuild the connection to the manifold as does a new head, then throw a new head on there.

As already stated above, do not let anyone try to burn in a seal with a welder or torch, it will not hold.

 

http://www.repairengineering.com/keensert.html

Just put a Keen Sert in there and call it a day. I really doubt you need to go buy a new head unless someone got really crazy with it.