check your local auto parts store. most will sell drain plug bolt assembly made to install on things like transmission pans which normally do not have drain bolts. unfortunately, you are going to have to remove the pan, because the nut will go on the inside, and a bolt with a hollowed out and threaded center will screw into this nut. you will then remove the center bolt to remove the oil. however, if it were me, i would just weld a nut in there if i were taking the pan off anyways.

 

If you weld a nut into the interior surface of the oil pan, there will be a lot of residual used oil left in the motor when you do oil changes, unless you account for this with some type of passages machined into the nut.

 

This is a nice convenience item, speaking of oil drain bolts:

http://hometown.aol.com/qckchanger

 

i would actually weld it to the outside of the stock hole, so that all the oil will still be allowed to come out for oil changes. i wouldn't worry about warping it. it's towards the bottom, far away from the pan mounting bolts. i agree, though. the correct way is to replace the pan. he seems like he doesn't want any down time, though.

 

Remove the oil pan and have a Timesert installed in the oil pan. This will restore the original threads and will allow you to use a original drain bolt. Also as previously suggested, a helicoil would be a good option as well.

 

Dude I feel your pain. The ft/lbs on the tech manual is way too tight. I did this myself a little while ago and ended up just taking it in to the dealer and having a new oil pan put on. Bottom line I didn't want to dick with it. I was contemplating reaming it and rethreading it but the parts and labor was 150$ Worth my time because my job takes the rest of it away.

 

Isnt it easy to change the sump? Dont know the cost but it must be worth looking at replacing. I am a little confused as to how you did it...you didnt overtighten it by the sounds of it, did you cross thread it? How far did you get it in? If you just wrecked the leading edge of the thread you might be able to clean it up if you can get a good look at the thread, if you wound the bolt a decent way in it is toast!

 

shit man.... find the the nearest salvage yard with a smashed R1 in it and buy the pan from them. i wouldn't do anything less than replace the pan.

 

Any decent automotive machine shop could put a heli-coil in. $30-$40 tops