Well for those interested.
Unfortunately EVGA could not help with replacement blocks - although I did not expect they would have these blocks lying around. Anyway...
I purchased a G1/4 BSP Tap (parallel) with a T-Bar wrench and used the Delrin thread on the other side of the block as a Guide. Using some lubricant (non-conductive) on the Tap piece I was able to create the thread successfully. However the block exposes the copper underneath the Nickel plating. Not that I see it when the fittings are applied. Clearly Swiftech machine the threads then do the nickel plating. How they missed the thread is a mystery - or is it??
Creating a thread is made simple with the right tools and size. The key is getting a strong guide to make sure the Tap remains straight. If you are attempting to do a thread use a drill press or something similar. Youtube has a number of good guides on this. I was somewhat lucky in one sense that the Delrin side of the block had an existing thread so I used that to Tap straight through.
The Thread on the Delrin was NOT impacted as the Tap was the right size. In fact if you have issues with any existing threads use the Tap to straighten any existing threads. As you know Copper and Nickel are soft metals and threads can bend.
Key Outtakes:
1) Purchased a G1/4 BSP Tap that has a Parallel shaft (no tapering on the Tap for my use) + T-Bar Wrench
2) A Guide to keep the Tap Straight
3) Lubricant (Non-Conductive) - I used INOX others use Magic tapping fluid
4) Use a very fine file (nail file) should any metal burs occur after the Tap
5) Wipe clean making sure no metal filings get into the block. Worth flushing the outlet with distilled water thereafter before installing to the rig
6) Test a fitting and flush the block before installation
Hope this might help someone in the future.
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post edited by AVictorD - 2015/04/11 20:08:58