Go to Ace Hardware and see if they stock the tap you require. I am a toolmaker with over forty years of experience in this business. Though I possess nearly every tap and die known to man, occasionally I have to make a trip to the local ace hardware store myself. if it is a one-off use on aluminum or mild steel, don't fret about purchasing a tap or die made of hardened tool steel, but if you plan on using it in more of a production role, then go with a ground high-speed steel version. A good source for higher quality tools is MSC Industrial Supply. They have been my "Go-to" resource for many years. good luck and should you require any technical advice, do not hesitate to contact me. My name is Tim, and I will give you any help that I can.Tonight I took an imprint of the threads in the hole with some hot glue, and when I held it up to the bolt (7/16-20) I was very surprised that it lined up perfectly! It looks like its a little off on the left edge but thats just an optical illusion due to camera angle. It really was a perfectly alignment all the way across the contact area.
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This makes me wonder if I can/should just put the bolt back and force it.
I guess in the end this doesn't really change my plan, I should just get a 7/16-20 tap and it will either slightly expand the diameter or clean the threads or whatever the problem is, it should fix it.