Jeff, good point, a BB tapping tool would come in handy for the types of bikes I work on, just to chase the threads and make it that much easier to work on them.
Bill, I considered a LBS but talked myself out of it for a few reasons. There use to be one about a mile from my house, super convenient, knew the staff, very helpful. Unfortunately a few years ago it became a Trek shop, different management, different vibe. More recently they moved, so I don't even think about them any more as an option. Also this time of year is when people take their bikes to the shop for a tune up, so I would have had to wait. Better to buy or make a tool to solve the problem.
I was successful after making a couple variations of the thread chasing tool as was shown in the u-tube video Garth provided. It did take a time and a dental pick to get the threads cleaned out. They weren't crossed threaded after all, just something which was very hard, maybe thread lock or dried grease/gunk, I'm not sure which. The first iteration was to use the Dremel cut off wheel to make slots across the threads of a sealed BB cartridge. That cleared the threads on another frame, but did not budge the Sequoia's threads. I figured the threads were too soft for the task, so I did the same to loose ball BB cups since they are a harder steel. I also bolted the drive side cup onto a 1/2 threaded rod so that I could turn it with a wrench (see picture). I installed the left side cup to help the tool stay aligned with the threads. This worked very well with a lot of oil and back and forth turning of the tool. I was able to turn it in almost all of the way in. I then removed the tool and checked the threads. This is when I saw the hardened material in the threads and started to use the dental pick to scratch it out. I then used the tool a couple of more times to get all of the material out. Now I can thread a cup or sealed cartridge in by hand.
The project is a '92 Specialized Sequoia, lugged frame, great shape, purchased from list member Eric L a couple of weeks ago. Converting it from 27" to 700c will allow 32mm tires and will replace my Surly Pacer as my club ride bike. A classic sport/touring rig. Riv content: somewhere, someone said, Grant was quoted as saying it was the best bike he had ridden, or something along those lines, at the time of the interview.
Thanks again Garth for the video, it really helped!
JohnS