aluminum thread repair

[JohnC]

The project(installing rack spacers) started off innocently enough, I figured, how long could it possibly take?

Well, as i was begining to torque the last bolt that attaches the rack to the chassis the threads stripped! HOLY CRAP!? WHAT THE F#$@!?

Turns out the threads had been stripped before and repaired with helicoil.

I noticed this AFTER removing the rack from the car (which can be removed without removing the entire axel assembly.)

I obviously don't want to use Heli-coil again
so the only other choices are

1. fill in hole using tig and re-tap.

2. use Time Cert or some other threaded insert.

3. tap to next larger size.

I was thinking about buying the time cert kit and using it to repair the rack/pinion.This would be good practice for later when the engine rebuild comes along (i anticipate two rebuilds).

Thanks

[5axis]

John, I think you covered most of your choices. The quick fix would of course be re insert it with a Helicoil or Timecert. Trying to tig a Fkd up hole is pretty tough because of the small diameter vs depth. A good way to handle this is to drill and tap for a significantly oversize aluminium plug.
Make the plug long enough so you can turn it in with vice grips, go until it bottoms so it kind of locks itself. Then cut it off and TIG weld it with good penetration. Last grind/machine and polish the plug flush. If done by a good welder it will be very hard to see any evidence of a repair. The good news is with aluminium,a file can do the machining part.

david 89 turbo cab

[This message has been edited by 5axis (edited 07-09-2001).]

[Early_S_Man]

John,

The threads are 'standard' M10, so it would be the same TimeSert kit as for the head studs. Be sure to order plenty of extra inserts, as there can be quite a delay if out of stock!

But, if you can stand the delay to get the TimeSert kit, it is probably the way to go. Don't forget to use Heavy Duty variety of Loctite -- red or orange, to secure the insert!

------------------
Warren Hall
1973 911S Targa

[JohnC]

Thanks for the replys

yes the aluminum plug/tig would be quicker but i will need to use the time certs later.decisions decisions hmmmmm?

My next question is: How diffucult is it to use the Time-Cert? I realize a good drill press will be needed (which i have access to).The operation is a simple drill/tap/screw in insert right?

Are there any other concerns?

Has anyone out there ever screwed up the installation of a time-cert?

[john walker's workshop]

helicoils and timeserts are about the same thread size. try a 10mm vw case insert and cut it to length. i think it has a 14mm thread

[Roland Kunz]

Hello

Just short.

Depending on year the steering racks have a heli coil insert from the factory.

Heat or even welding on the steering rack is a no no.

Time serting does have limitations on thin walls.

If everything brakes then drill the hole trough and cut a long thread upwards into the new flesh.

If it will not have enogh the gind a flat surface on the upside and use a washer $ poly stop nut to secure it.

BTW one customer brought a pump steer kit from the staates and the screw had a non DIN conform thread ( BSP ? ) and ruined his part. He then moved to time sert and the "thin" wall craked under the wedging.
He came then saturday evenening and if I could do a miracle and save him the 500$ steering rack and the car was also his daily driver. Ended with the upper constellation.

Grüsse