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Isn't a helicoil longer than the width of the cover hole? I guess you could put in the heicoil with permanent thread bonder and after it dries, cut off the excess that sticks out on the top. A long bolt and nut seems the simplest fix to me.



Helicoils come in a variety of lengths, you can buy a KIT that is a little more costly than the Ace hardware kit that has 3 different length coils .

Or you can trim a as many turns off as necessary BEFORE installing one by using a dremel with a tiny cutoff wheel , I've done it multiple times.