OK, here's the update on the pan-from-he!! project. Got the rest of the bolt out on Sat.
Hole was pretty banged up, but cleaned up better than I thought when I ran a tap into to it. I used a tap guide, so I know it went in straight. Oh and tap sockets are a godsend in that tight space.
I decided to give the Permatex epoxy solution a shot first. It will fill any gaps on the sidewalls of the bolt hole and I still can go with the TimeSert if it doesn't work. I am a little nervous about the need to drill out a bigger hole for the TimeSert as I think Chas is right that the boss for this hole doesn't leave much margin for error.
So current status: Pan is back on the car, all of the bolts are in, but just snugged gently. My torque wrench seems to be acting up. It's one of the cheap "click" types and didn't seem to be functioning properly, so I ordered another one and will wait to torque the bolts until I get it mid-week. I don't want to over-torque anything. There is still a question as to whether that Permatex hole will hold the torque, but i will find out and can always do the TimeSert if I need to. I know my father has had good luck with that solution on manifold bolts.
Oh, I couldn't get the windage try to fit over the cross rail, under the rotating assembly and over the
oil pick-up, so I am going to pass on it this time. I cut the serrated-head bolts from 3/4" down to 5/8" instead. I will admit to having limited patience with messing with the windage tray at this point - especially on such a beautiful day when I was under my car rather than driving it.
Anyway, hopefully I will be good to go for the Middleburg cruise this weekend. And hopefully leak free....