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Helicoil or Braze?

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Andy

03-20-2003 06:39:43




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Working on an exhaust manifold from a Wisconsin V4 where a 5/16" tapped hole has very little thread left. At first I was thinking to Helicoil but the casting is only about a 1/4" thick. I�m now considering installing a stud in what threads remain and brazing it in place. Any thoughts on pros and cons of each method? If I try to Helicoil, I am somewhat concerned about drilling and tapping by hand (vs. doing it in a mill or drill press) and keeping everything straight and on center.

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J Boyce

03-20-2003 18:14:30




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 Re: Helicoil or Braze? in reply to Andy, 03-20-2003 06:39:43  
I am a mechanic by trade. At our shop we use what could be the best thread repair kit availible to the industry. It is Time-Sert by Wurth tool company. It will work in cast iron. You will have to take your time and be cautious but it is an almost gauranted and permanate fix. A Healy coil can back out, especialy in cast iron. Give it a try!



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Andy

03-20-2003 18:57:31




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 Re: Re: Helicoil or Braze? in reply to J Boyce, 03-20-2003 18:14:30  
Thanks. Do you know of any online sources for these? I did a Google search and found lots of references to the product but no retail oultets. The wurth.com website didn't yield much either.



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Thanks!

03-20-2003 16:49:03




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 Re: Helicoil or Braze? in reply to Andy, 03-20-2003 06:39:43  
Thanks for the great ideas guys. I was hoping to do this on the engine, but I think I better take it off and weld it up or have a machine shop install a Helicoil.



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a different Andy

03-20-2003 14:57:28




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 Re: Helicoil or Braze? in reply to Andy, 03-20-2003 06:39:43  
I would weld it with nickle rod. pre heat it to 400-500 degrees, weld it,(use narrow passes as they create less tension on the weld) and bury it in sand or wrap in insulation to cool slow.



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Fuzz

03-20-2003 14:52:03




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 Re: Helicoil or Braze? in reply to Andy, 03-20-2003 06:39:43  
Is it possible to go up to a 3/8" dia. stud?



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Earl S.

03-20-2003 12:38:55




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 Re: Helicoil or Braze? in reply to Andy, 03-20-2003 06:39:43  
Do not weld. I would use the Helicoil. If it is a head stud just put the head back on with a few bolts and use it as a guide to drill straight. Make sure you use the recomend drill for that helicoil. Earl



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Earl S.

03-20-2003 12:43:05




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 Re: Re: Helicoil or Braze? in reply to Earl S., 03-20-2003 12:38:55  
I need to correct myself .On the manifold welding would be a fine fix. Earl



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Slowpoke

03-20-2003 11:05:30




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 Re: Helicoil or Braze? in reply to Andy, 03-20-2003 06:39:43  
Maybe you can put a 5/16 nut on a bolt from the front side, snug the nut down and braze it. Remove the bolt. Then when you drill, the brazed nut will guide the bit straight. Tap for the helicoil thru nut and manifold. Grind off nut and install a Helicoil. They are made for 1/4 material. OR leave the nut on and use a longer Helicoil if looks are not important. Or do no drilling and taping and just use the nut.
Or make the hole the size of a 5/16 'T' nut (the kind that's used in wood) and remove the three prongs from the nut flange. Take a long piece of wire, poke it thru the hole from the outside of the manifold until it runs thru the manifold and out the back. Run the wire thru the 'T' nut and fasten it to a small nut. Pull the wire back out and the 'T' nut will come thru from inside the manifold. Hold it tight and straight with the wire and braze the section that protrudes thru the front. Cut the wire and the small nut will drop out. OR you can also use a full thread 5/16 screw to hold the 'T' nut instead of a small nut. Thread the 'T' nut on the screw and braze the wire to the very end of the screw. Pull the screw thru the manifold with the wire. Now you have a 'handle' to better hold the 'T nut straight. Braze the 'T' nut to the manifold. File off the wire and cut a hacksaw slot on the end of the screw. Use a screwdriver to back the screw out of the 'T' nut and out of the manifold. You now have 3/8 of threads with a large base preventing pull-out and only a small protrusion on the front. The idea is so crazy it might just work. Good luck on the fix.

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mj

03-20-2003 09:20:01




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 Re: Helicoil or Braze? in reply to Andy, 03-20-2003 06:39:43  
I assume that this hole is on a flange with some space behind it? If so, you can thread a bolt thru the flange far enough to accept a 5/16 nut. Snug the nut down (to align the threads) and clamp it to the flange. Then remove the bolt and braze or weld the nut to the flange. Run a tap thru the hole to clean up the threads.



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Andy

03-20-2003 09:32:30




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 Re: Re: Helicoil or Braze? in reply to mj, 03-20-2003 09:20:01  
It is a thru hole, but it goes directly into the exhaust passageway, so unfortunately it's not accessible from the other side.



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bill b va

03-20-2003 12:19:49




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 Re: Re: Re: Helicoil or Braze? in reply to Andy, 03-20-2003 09:32:30  

can you braze the hole completely shut drill and tap ?



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Andy

03-20-2003 12:33:21




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 Re: Re: Re: Re: Helicoil or Braze? in reply to bill b va, 03-20-2003 12:19:49  
I may go that route if it turns out that I have to remove the manifold- then I could take it to a machine shop so the drilling/tapping will be more accurate. I just don't want risk ruining an otherwise good manifold.



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