Ok. I got to the pan a bit tonight, after rebuilding a Mitsu 3.0 v6 all day. You know if you crack one piston ring, there's no where to get another single ring?
Had to spend the day in a scrap yard finding a 3.0 without heads on to get ONE ring out of. But that's another problem...
I drilled out the mount holes in the pan with a 27/64" bit. Ran a 1/2"-13 tap down nearly all the way in. The 1/2"-13 is the outside size of the keyserts i'm going to use. Then i needed to heat the whole pan to do the aluminum brazing. Tried with my kerosene bullet heater...i've measured that thing to 600 degrees. Unfortunately, it has a thermostat that kicked it off 'cause it's already 90 degrees here! Tried a heat gun and after a half hour, still not hot enough (the brazing rods need 735 or so and aluminum wicks away heat quickly). Had to go to the gas grill method to get any heat. I suppose it doesn't help having the 1/2"-13 bolt in it. Wanted that to keep the threads straight.
Finally got to a reasonable amount of heat (read: a LOT) and heated locally with a propane torch. Once you get the rods to start melting, it's pretty easy to work with. Didn't really build up cleanly like i wanted, but I did get probably 1/4" or so. Pulled the bolt after getting one done and moved it to the next hole...rinse....repeat.
Let it cool a good long while after all four were done up then just hand filed them flat. Was debating whether to add more to one, but it takes too long. Got the four pads filed down, using the pan surface and a straight edge to get the angle close. I tried to run a keysert down in one, but the threads are a bit tight. I've chased them with the tap again, but still a bit snug to get the insert in easily. Think i'm going to slot the insert so i can get some torque on it (knocked a couple pins off of one). I'm going to run them just flush so there's a little steel there to clamp / beat on.
I'll get some more pics of the finished product when it's a finished product...