<VV> How do I fix this hole in my head . . . .Corvair that is . ..

[tkalp at cox.net]

This morning just pulled the head on a clubmember's 102 hp Corvair.  It was a freshened engine, that just wasn't running smooth.  When we ran a compression check found #4 cylinder was down to 90 lbs., 30 to 40 lbs lower than the other cylinders.  During a "leakdown" test where we put about 30 psi air into the cylinder to see where it was escaping . . . got a suprise, it wasn't intake, or exhaust or past the rings it was blowing out of the cylinder head down into the lower shrouds, not at the gasket area.

After the head came off we found a pin-hole in the combustion chamber at about 7 o'clock and 3/8 " in from the gasket surface.  The head has a fresh valve job and would prefer not to have to disassemble it to have it welded.  Would it be reasonable to drill and tap for a threaded plug?  Are there aluminum plugs available or would steel be Ok.  Any and all tips would be appreciated. The clubmember took this week off to work on the car and would rather not spend the week waiting on the head at a machine shop.

Didn't have my camera with me, but should have photos soon.  Anyone have this happen before?

tkalp,
wichita, ks