Thanks Marty. I have some brazing rod and tried to braze one of the fins. Couldn't get the head hot enough to make it stick. If this won't work I'll start rebuilding the original head, replace the save a thread and just ride the bike. Too bad, the porting seems to have made it faster.
To summarize what I've learned in this multitude of errors is this.
I should have fixed the spark plug threads while the head was on the bench.
( My reply to Dave's PM)
"After what I went through I can only say this.
I should have gone Helicoil.
The Time Sert would have been better but for one plug it wouldn't have been worth the $2/300 just for the tool. All four maybe.
The Save A Thread would have worked being the tap would have followed the threads and been straight. I wouldn't recommend it due to it being so large it exposed the cast in seat thus a shorter insert was needed. Sealing it was another problem and after three fails the only thing left was the Big Sert.
The Big Sert is big enough to fill the hole using a M 18 1.5 tap. Using the tapered tap first allowed me to correct the bad angle caused by the first CHEAP tool and no instructions.
My next mistake was not doing my research before I bought anything. That led me down a path I'd wish on no one. Though none of the kits had instructions there is the web and I could have saved myself time and money.
The Helicoil would have worked but if it failed the Time Sert wouldn't have been an option. It's one or the other.
The Save A Thread could have worked but the cast in valve seats are too close so grinding it shorter to 15mm was the only option for it to fit flush so the gasket would seal on the head.
The Big Sert is large enough so the hole could be tapped to fit.
Here's a break down on the sizes.
Time Sert 15.56mm
Save A thread 16.71mm
Big Sert 17.77mm
The good thing about all this is the plug seals on the Big Sert and you can't tell it's been repaired with the plug in.
My son works for Amazon in SF. He and his wife have been holed up for over a week. Only allowed out for groceries. He told me that Amazon's online software has developed issues thanks to the millions of people looking for toilet paper online.
I have a couple of Z1B's restored, an '80 KZ1000LTD restored, a 1981 KZ550 restored and a 2008 KLR 650 for off road fun. My wife has a 2019 Suzuki DR 650 for on and off road.
The head is worth keeping so repairing the plug threads was a must. The light porting made a big difference. I can tell when I get to 6000 RPM it starts to pull stronger and wants to dive into the redline. I pulled onto the highway and wrung it out in three gears. It wanted more but I was already at a ton so I backed off. Third was pulling like the first two gears and I'll bet 4th and 5th will do the same. I'd better beef up the frame before I get myself in trouble.
I was trying to point out the depth needed for the inserts. I'll pullout the other head and measure the depth of the holes. 15mm might be the longest insert that can be used. 16.8mm is the common size and may be too long. We'll see.
The herd mentality is alive and well.
Steve, I'm picturing you in the Mad Max movie! On the laws side! Blasting through the desert, with your side arm strapped on!
Blasting into a town. To find Beer and Smokes for your fortified compound!! Out running the Looters! Lord almighty Will it come to this??
Livin in "CheektaVegas, NY
Still have a Kaw! 76 KZ900 Pro-Street.
Went thru 25 of these in 40 yrs.
And The Old Girl, Harley 75 FLH Electra Glide,
Old faithful! Points ign. Bendix Orig. carb.
I hope not. Won't say anything about guns online but lets say we out here aren't easy marks. If they think they can leave the city and come out here to take from us they have another thing coming. This shouldn't last much longer as long as we follow the guidelines suggested. It's the people not the bug that's the danger. I had to work through other epidemics during my career and made it through alright. This one could be a killer for us old guys so keep safe out there and stay away from people if you can. The one thing that hit me the hardest was the Chicken Pox in the early 90's. My kids brought it home and I didn't know you could catch it again but it was like a bad case of the flu. There I was laying block with my two kids sleeping in the truck. It was miserable but we made it through and we will this one.
Like someone said it was made in China so it won't last long. I hope they're right.