Quote:

Yes it was leaking before, that's what started the whole screw up


K, that makes sense, are all your remaining threads now stripped? I am not psychic, but it looks as if the stud was not fully threaded in, when you pulled a chunk of aluminum head off. Have you chased the remaining threads with a bottoming tap and tried a new stud? Also the specified torque value for a proper crush on the Copper seal ring is in inch pounds, could you have exceeded that in your effort to get a seal? You only need the diameter of the stud, plus a thread or three to have the stud properly secured, assuming your threads are still 70-75% intact. Looking at your pic, I would clean the seal seat in the head, removing no metal, install a thread repair kit, if needed, clean and rehab the pipes mating surface (if needed), use a new copper ring and torque the bolts to spec and not one bit tighter. At this point, use the copper silicone you bought too. BTW, if your married to the idea of using a miracle epoxy to fix this, clean the to be repaired area with the hottest reducer you can find and scrub with a wire brush too. It also helps to drill shallow dimples in the aluminum to give the epoxy an irregular surface to bond to. I have had the best success with the products, Devcon and Belzona and unfortunately, they are not to be had on the cheap.