Getting Fed Up...

[CJFusco]

Ok, during my attempt to install the 951Max chips (http://forums.pelicanparts.com/showthread.php?threadid=326838&highlight=banjo+bolt), the banjo bolt for the KLR box snapped in half when I was putting it back in the box.

Another pelican member was nice enough to ship me a replacement banjo bolt ad gratis. Once that was taken care of, I brought it down to my mechanic because I didn't want to mess up extracting a bolt. He got the remnants of the bolt out of the box with no problem.

I got the replacement bolt in the mail today. Went to install it... and sure enough, the inside threads on my KLR box are stripped just enough so that I can't even get the new bolt inside.

So what's my next step? Buy another KLR box and declare this "lesson learned"? Or is there a way to re-thread what needs re-threading?

[Techno Duck]

Depending how screwed up the threads are you can simply retap the threads. If they are really screwed up, drill out the hole and helicoil it.

[CJFusco]

Originally posted by Techno Duck
Depending how screwed up the threads are you can simply retap the threads. If they are really screwed up, drill out the hole and helicoil it.

How would I attempt "retapping the threads". Sorry if it sounds like an ignorant question; this aspect of DIYing is new to me.

[EMBPilot]

you just need a tap and die set. its easy, but you need to go slow and careful.

[CJFusco]

Available from my local hardware store? How much is this going to run me?

[EMBPilot]

they probably sell them, home depot would have them to. They can be cheap or as expensive as you want to spend. They are made to pretty tight tolerances. U just need to take careful note to match the tap with the drill bit you'll use as a pilot, and the thread of the bolt you'll be using, you need to match them exactly. then its a matter of drilling a pilot hole, (just the next size up from what your using now), then slowly thread the hole, use oil, turn the tap slowly say, 1/2 turn in, then back it out one half turn, then turn it back in 3/4 turn and repeat. once its threaded, screw in the new bolt.

clear as mud?

im not familiar with what hardware your working on, material, size, ect, so im just giving general advice here. in order for a tap and die to work you typically need to have some metal left to work on as far as the wall thickness.

[VINMAN]

Originally posted by CJFusco
So what's my next step?

Buy a Ford!

[EMBPilot]

Originally posted by VINMAN
Buy a Ford!

and if you do, buy a monkey to connect any Oxygen sensor harnesses.

[CJFusco]

Thanks for the detailed responses, guys.

The KLR hole isn't too bad at all... it actually looks like it's stripped for about the first couple millimeters then it is fine from there on in.

Part of the problem is that I don't know the measurement of the banjo bolt-in-question. I know it's a 7mm head - not that that means anything. The threads themselves are very close together and do not stick out as far as a normal screw or bolt. Here is a picture of the banjo bolt side-by-side with the philips-head bolt from the KLR mounting hardware:

[Razorback1980]

CJ, take the banjo bolt with you to the local auto parts store. They will have a gauge that they screw the bolt into that will tell them the size and thread pitch. They will be happy to sell you a tap of the same size and pitch and you can take it home and try rethreading....meaning screw the new tap into the hole following the old thread pattern if you can using a little light weight oil. If you are uncertain, take the KLR off and take it with you to the parts store and if you go during the nonbusy part of the day, one of them will probably retap it for you.

If that doesn't work, then what you will have to do is take Jon's advice on the helicoil. You will then have to buy a helicoil tap and helicoil inserts and that will give you a drill size to drill the hole out to as Kevin outlined. Then run the helicoil tap into the hole (straight and following Kevins instructions of screw it in a little then back it out and keep it oiled) which will put new threads into your part. The threads will not be the right size you are looking for until you screw one of the helicoil inserts into the freshly made threads and then you will have new threads to screw your banjo bolt into. The helicoil kits I think are about 25 dollars. The new tap the size of your banjo bolts will be about five or six dollars. You will need to weigh that against the cost of a new part. The six dollar tap if done correctly will probably fix your problem if you still have threads in the bottom.

[Techno Duck]

Well first of all that is a coarse thread screw you are comparing with. Take a vernier caliper or mic and measure the diameter of the threads on the bolt. Home Depot or where ever will have the tap and die kit, same with Sears.

Helicoils i have only been able to find at the local specialty tool place in town. I think my local PepBoys might carry them, but i cant remember for sure. The helicoil package you need to buy will be specific for the thread diameter, on the back will be a chart which says what drill bit you need to drill the hole out to. It will include a special sized tap and the thread inserts.

[p-talk]

Yeah, take that bolt to the local hardware store, autoparts store etc. and find a match. That will tell you what thread the bolt is. Then you can get exactly what tap you need to cut decent threads in that hole.

I bought a tap and die set a few years back. I don't use it too often, but when I do it REALLY comes in handy.

Good luck man, you'll get it, just be persistent and keep researching when you have questions.

Originally posted by CJFusco
Thanks for the detailed responses, guys.

The KLR hole isn't too bad at all... it actually looks like it's stripped for about the first couple millimeters then it is fine from there on in.

Part of the problem is that I don't know the measurement of the banjo bolt-in-question. I know it's a 7mm head - not that that means anything. The threads themselves are very close together and do not stick out as far as a normal screw or bolt. Here is a picture of the banjo bolt side-by-side with the philips-head bolt from the KLR mounting hardware:

[CJFusco]

Thank you all for the detailed responses.

I called my friendly, local, family-owned hardware store today, and they urged me to bring the box down so they can take a look at it and see if they can re-thread it easily. Failing that, I will just buy the tap-and-die set and go from there.

I'll let you know how it turns out.

[EMBPilot]

im 99% sure the pitch on the banjo bolt is 1.25mm

[CJFusco]

Great, thanks. Every bit of knowledge in this helps.

Next time we have a Pelican meet involving the CT/NY/NJ area, I'll buy EMB and TechnoDuck a beer. Vinman can sit and watch them drink their free beer

Thanks also to the Texas guys... but I'm not driving 3000 miles to buy you a beer!

[CJFusco]

I went to the local, family-owned hardware store in West Hartford, Pfau's. They were happy to help me.

It turned out that only the first row of threads was bad, and they weren't even stripped, just worn a little. No tap was needed, just a 5mm metric bolt. Wish I thought of that...

Expect a write-up of the 951Max chips tonight...

[EMBPilot]

NICE!

[nynor]

nice work, CJFusco. glad the bolt got there in a timely manner.

[Razorback1980]

Sounds like the one in Salt Lake that contributed more than just advice is the one that deserves the beer. Glad you have it fixed CJ.

[nynor]

having a noon beer right now. i have a whole keg in the fridge. too bad none of you live close enough to help me out with it!