Powderman,
Thanks for the response, this makes total sense, as the front that this guy just gave back before ruining it does have those "stake" areas drilled out a little but but perhaps not far enough. I'm going to hit them one more time, and use a proper tool (I have learned the hard way too many times to not shortcut things, and I'm embarrased I'm learning it again).
BobbyR,
Yes, I'm quite sure "buddy" did not quite have a handle on what he was doing, or just didn't stop and ask himself "what's wrong" soon enough. I apprecaite the insight making my own tool, I had originally thought of getting a large socket and filing down pins/notches to the correct size, which seemed like a bit of a pain (not in retrospect I guess), but I'll take your advice for sure. Seems much simpler.
I'll do the research obviously, but might you be able to save me some internet search time and know the thread pitch off the top of your head for the correct tap?
Cheers, and thanks again to you both.
Andy