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The sump is probably repairable with a timesert or similar thread insert, these are nomally used to salvage magnesium 911 engine cases. The sump will need to come off to do the repair though, much cheaper than a new sump.
 

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The swarf will come out. Use a very sharp drill, slowly & carefully, and a spiral-fluted tap. Any loose swarf should get flushed out by the flow of oil as the initial drill breaks through - likely to be a slightly messy occasion! Tiny bit of cloth wrapped round the drill may help stem the flow of oil all over the battery-drill! Maybe I'd start with a 3mm to minimise the general mess, then gradually open it out in steps of 0.5mm up, which would also minimise swarf.
 

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Discussion Starter #24
ok, it's done, was removed by the mechanic with one of those bolt removal tools, had little issue getting out, then since we didn't have a suitable replacement, he re fashioned the bolt, and welded a good sized bolt, he said there'll be no more issues next time, we're all good :)
 
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