No worries.. Appreciate the help!

Im thinking simply rotate the pulley until the belt is tight then snug the bolt down to 30-40ftlbs..

However, at this point, fixing the water pump bolt so it doesn't leak is the major problem. Good 'ol JB Weld is not up to the task of holding the stud I threaded in the drilled out hole...

 

You are most likely going to have to re-tap that hole and use a larger diameter bolt to secure it properly. Remember, I think the torque spec for the water pump to block spec is around 8 to 10 foot pounds - it's not much. I would hate to see you snap one putting it back on.

 

Ya, 7 lbs.. I believe this pump had leaked for awhile due to the last person over tightening as 3 bolts were corroded and one was snapped.

I cant really retap as when I was trying to drill the old one out, the drill wandered and its too close to the edge of the boss. Thought if I filled the hole with JB Weld and threaded the new stud in, it would hold. So far, no go. I tried welding, but all I have is a MIG and it doesnt do cast very well..

 

You've got your work cut out for you with that job.

Maybe use a modified valve cover stud combined with some JB Weld?

 

I used a long bolt then cut the head off. JB Weld tends to tick me off as the holding strength is no where what they claim, but I thought it would hold at least 60-80inlb's..

 

Well, put all back together Thursday and its still holding, so thats good.

For the water pump broken bolt/stripped hole, I filled the hole with JB Weld again, dried it, tapped it. Coated the pump in RTV Blue, finger tightened the bolts and waited an hour for the RTV to set up. Then I used a modified fender washer on the bolts on either side to act as load spreaders, then tightened the bolts to 8ftlbs, and the fender washer ones to 10ftlbs.. The broken one I coated with JB Weld and threaded it in until touching, then 1/3 to half a turn to snug. Thats all JB Weld will tolerate. Let it sit again overnight to allow the RTV and JB Weld to fully cure, filled her up, and put it through two heat/cool cycles before test driving.

The tensioner I just tightened to 400inlbs/33ftlbs after adjusting the belt tension. It just tightens to the block.