Best instant 'metal' to use ??

[Thezedsintheshed]

Dont be too hasty to rule out welding it in situ option, if there is enough room to prod JB weld around ther area with your index finger then there will definatly be enough room to get a Mig torch in there.
If anything , given that the Saxon has a Rickman type frame then there is probably more room to get at the exhaust port area of the engine than with the standard Kawasaki frame set up.

Ask around your local welding / engineering company's to find someone who has a Synergic Mig set up.
A Synergic Mig set up can literally mig weld 2 coke cans together

It produces a Tig quality finish and in the right hands will produce a quality repair to your cylinder head without having to remove the motor from the frame or remove the head from the motor.

[02GF74]

Thanks for all the suggestions guys, though the

What I propose to do is to make a mould for the outside shape by smearing another lug with vaseline and using JB weld 'putty' to replicate the shape. Once that has set I will remove the cam retaining cap and clinically clean all the area.

never done that so notsure how successfl it will be but I reckon you will push the vaseline outof theway when slaaping on the JB.

maybe some like cling film or wax release agent, the stuff used to cover moulds for grp fabrication would work better. guess it will involve some trial and error.

[Big Fluff]

Well, I made a mould out of JB Weld 'stick', lined it with cling flim and held it in place with a compression spring. I then gently heated the JB Weld 'resin' and coaxed it down the entrance hole in order to fill the void.
It seems to have gone ok but time will tell in the morning when I remove the mould
Hopefully it'll be a simple case of drilling, tapping and inserting a helicoil to complete the job

[Big Fluff]

Just an update.........
It worked !! Popped a helicoil in afterwards, clamped down fine and the lug looks almost as good as the others.
Well chuffed with the result

[Pigford]

Well done Will....... Thats wot its all about mate, "triumph over adversity"

[02GF74]

looks quite successful!!

hopefully it'll survive the real test once you get the engine up to temperature.