Thanks Gene. Ultimately a new crankcase was made after the alum solution failed to do anything useful on that particular tap. Because of the extended alum bath, it also horribly etched the aluminum. Maybe this alum solution breaks down regular HSS taps as claimed. Who knows, its now history. As mentioned, this was a high quality tap that happened to be coated & maybe that slowed the erosion to a crawl. The tap breakage itself was entirely my fault by insufficient cellar depth, tools & lack of proper technique involved. Core drilling of a sheared off tap is something I want to experiment with on the side with some scrap so I have that trick up my sleeve just in case there ever is an unfortunate 'next time'.
The crankcase assembly has progressed as below. Once I get my new mill issue sorted out (hopefully soon!) building on the radial will recommence with 5 cylinder assemblies. I've got a lot of pictures to upload & document, but I'll do it in a proper build thread. This has been an overly long journey dragged out by regular life stuff & my machines, but I will persevere. To be continued!