pulled threads on I/C mount
 

Take a look at this. The boss was heli-coiled, but not correctly and the I/C was not completely attached at the back. It blew the I/C off and pulled the heli-coil out. I think I am going to install a time-sert.

http://i475.photobucket.com/albums/r...1029-00597.jpg

I just had the same thing happen. I just put in a new helicoil and all is well.

For my experience, the magnesium cast was cracked to where it wouldn't hold a coil any longer. So I just tapped the hole as best I could and installed (glued in) a stud.

What about sleeving the outside with either an adjustable clamp or metal sleeve for reinforcement?

installed a new helicoil last week, tiny tiny bit of JB weld...its all good.

YUP... Happened to me also... :(


Walt

Seems like this happens alot with the B&B intercooler. I think the machining fixture they use over there needs to be tweaked and the castings revised so that the holes get machined in the center of the mounting bosses.
My B&B also has to be "persuaded" to get the bolt to line up with that hole in the bypass housing. I have never stripped or pulled a mounting bolt yet.

----- Maybe you guys are running too much boost and just yanking the studs right out of the threaded holes? Kidding.
Seriously though, there is alot of vertcal force trying to rip that intercooler of its mounts though. Figure 1bar boost acting on 2 circular areas of 3 inch diameter yields a force of about 102lbs trying to send the intercooler thru the decklid. Dont know if people realize this most times.

Here's a shot of mine. You can see where the casting actually broke off at least an inch. I drilled through and past the break into solid metal, tapped, and inserted a threaded stud. Glued in with JB, it's been holding for several years now.
http://forums.pelicanparts.com/uploa...1320086793.jpg

I really like the stud idea. Should make it easier to get everything lined up too. I may just have to try that trick!!!

I like the stud idea also, but I've already fixed it with a time-sert I had on hand.

http://i475.photobucket.com/albums/r...1031-00611.jpg

Time sert FTW :)

The stud thing I did out of desperation, but since I eventually did my unconventional McGiver'ish short-neck IC boost recirc manifold delete thing, that IC mount was just "floating" since that section of the recirculation manifold is no longer connected to anything other than the turbo intake hose and standalone BOV. But since that mounting point is critical to keeping your IC from flying off, I eventually built an additional bracket to sturdy things up. See the pict.
Sorry, a little off-topic, but I ran with the stud in the stock configuration for quite some time before further mods.
http://forums.pelicanparts.com/uploa...1320111614.jpg