[Walt Fricke]

I get my Helicoils at my local hardware store. However, it is not your usual hardware store. Easy to get the stuff via Internet, though.

You purchase a Helicoil set (maybe half a dozen of the inserts, plus tools) in a package. You drill your hole per specs, then tap with the tap which is (I think) in the set, or at least is specified. You use a modest plastic tool to insert the Helicoil, and then break off a locking tab. Pretty simple. I may have done my first upside down under my car repairing the transmission mount's threads.

There are other devices. While the Helicoil is, in fact, a coil, you can get things which are just a larger stubby stud with a drilled, threaded center, and a screw driver slot on the top. Drill and tap to the OD, screw it in. Done. These usually have some thread locking stuff on them, and good old Loctite is readily available. No special tools other than the right tap. I used one of these when I found my curiosity about what was inside my rack and pinion led to a buggered threaded hole for the cover.

Our host sells something called Casesavers. I think these are sort of like the above. And there are the Timecerts, but those require a really special tool called a rolltap. And using them requires a large supply of really fresh, sharp taps per a machinist I know, in order to do the job we mostly call on them for - 911 case headstud threads.

No need for fancy stuff for the simple fix to your basically simple, if irritating, problem. You will seldom have to remove your starter, and this fastener is not really subjected to much force and so on.

Take a look at Maryland Metric's array of fasteners. I know that double sized studs exist, so it would be a question of sizes available. I've thought of doing that on my cam carriers, so I could use the later O ring gasketed valve covers which use the 6mm stud. Less work than using inserts and separate studs.

But I think you are wise to abandon the bolt solution. If trying to remove the starter in the car, you don't want to have to put wrenches on both sides of things, if that can be avoided.

Walt