Thanks for all the comments and advice in part I. I'm gonna try to fix this mess if for no reason other than to see if I can do it.
I've fabricated a collar to act as a mold and to give the post lateral support. You can see it in the photo. I'll clean the surfaces, install the threaded insert in the void, place the collar around the post and fill the void with either molten lead (I scrounged a post off an old car battery)or lead solder. (If I do the lead I'll do it outside with good ventilation.) After that I'll drill out the new material to access the threaded insert, clean up the surfaces with a file and put it back in the bike. The collar will stay in place.

Looking on opinions on what would be better. lead or solder. Other thoughts or opinions???

 

I'd use solder, preferably electronic grade. Solder has additives in it that make it flow and bond better. Electronic grade melts at a slightly lower temp.

Be sure and coat everything with flux, liquid or better, paste flux if you can find it. I'd use a big soldering iron. NO FLAMES

 

Canadians are dumb.

 

I have no suggestions, but I'm looking forward to seeing the finished product.

 

Have whomever is watching hold your beer.

 

You can get lead at any home supply store.......flashing for chimneys!

 

How about having the bolt already screwed into the block before filling with lead or solder ? Maybe search for a suitable coating for the threads to prevent adhesion.

 

Ooh, cool idea.
How are you going to do the melt?
You do grasp the concept of "volume" needed?
"lead" is going to be pretty freaking hot,, without some sort of protection molten lead even at 400 when poured into your collar WILL burn through he plastic in a heart beat so I'd skip that.
Have you checked adhesion of a solder to the post?
Tin the post with a solder,(make the pour compound stick before the pour) lay a tight fit base of cardboard on the plastic under the collar, a release agent of even Vaseline on the stud and bolt should do,,
,, it's going to be all about the pour temp and the plastic.

Anyway's,, personally(?) I'd snap off the left side of the post,, turn the nut sideways, drill a hole for the bolt in the right side of the post that is properly aligned,, then solder tin the cable,, solder tin the post,, add the bolt, snug it, then solder the connection between post and cable.. Then tighten the bolt.

But the problem is,, some guy's have so many "accessories " that they need a 1/2 inch high stack of cables attached to the post

 

When I saw part I my first thought was you are nuts, kinda like 50 cents holding up a dollar. But I reckon that I have to admire your tenacity. Best of luck but hope you have somebody post here if you blow yourself up.

 

Make sure your roadside assistance is paid up.