Britbike forum Forums Thread Like Summary - Sheared fork drain plug bolt

Damn. Bought an A10, went to change fork oil and noticed the hex head was sheared off, I drilled a hole and have tried to remove the bolt but it's not working. I'm considering drilling the thread out completely, re-threading and fitting helicoils. Any advice appreciated over whether this would work, and what size helicoils to use. If the original imperial sizes are not available then I'll just convert to metric.

I have drilled out smaller, just slightly less then the threads (very slowly so as not to break the bit), ran a tap to clean the threads. If threads are then still bad, then used JB Weld to build new threads. The oil drain screw/bolt is real small, so not much stress on it, thus the JB Weld works fine.

Fork drain plugs are a right royal pain in the ar$e. The oil never drains properly and pumping the forks ensures it gets everywhere including on the tyre.
It is much easier to drop the fork leg out and turn it upside down