How To - Thread Repair In Aluminum
Topic: How do you repair stripped threads in aluminum?
Expertise Required: Intermediate
Estimated Time: About 1/2 hr per hole
- Small diameter drill bits (pilot holes)
- A thread-repair kit from these guys (Timesert)
- Drill Press - assuming you can get part up there
- Spring-Loaded Center Pumch
- Map-Gaas Torch - this is your most valued tool !
- Regular Drill
- Compressed air or vaccuum cleaner
- Tool for turning Tap and Rolled Thread Tool
- Try your best to get old bolt out. If it is sticking up at all, weld a nut onto the end of it. The heat will shock things a bit and help the bolt break free
- If that option isn't available, do your best to grind end flush
- Take super-extra-care and use the center punch to get a punch in the exact center (or as close as you can)
- Drill a tiny pilot hole all of the way through - taking care not to break off this pilot drill bit.
- Step up through different drill sizes until you come to the one you use for the Time Sert. Carefully drill that one - making sure you clear the chips often (pull up on the drill occasionally)
- Change over to the counterbore Timsert tool and counterbore hole
- Follow their instructions and install the timesert (don't forget the drop of oil on the thread expander tool
- Give it a blast of compressed air to clean away any chips - then hit it with WD40
TimeSert has some wonderful videos on their site. Please have a look at them.
Here's a few pics of messed-up threaded holes (in aluminum)
Copyright 2012 Capt'n Obveeus