Aluminum car parts are lightweight and durable. Strands cut from aluminum are prone to dislodging. This trend results in the need to install new threads to reinstall a fitting in a piece of aluminum. Replacement thread inserts are made of steel, offer a stronger pulling force than aluminum threads, and are less likely to break when installing or removing a bolt from the installed thread insert. Threads replaced with a thread insert will remain the size of the original stripped aluminum threads, allowing you to reuse the fasteners supplied with the accessories.
Step 1: repair aluminum thread
Secure the bit in the chuck of a 3/8-inch drill motor. Select a bit size specified by the Bit Set Hole Size Chart. Refer to the hole size chart in the thread repair kit to determine the hole size required to install the thread insert.
Step 2: repair aluminum threads
Apply cutting fluid to the bit and to the hole containing the damaged aluminum threads.
Step 3: fill aluminum thread
Drill through damaged threads with the bit installed on the 3/8-inch drill motor. Apply cutting fluid throughout the drilling process to prevent the bit from clogging with aluminum.
Step 4: repair thread
Tap new threads into the drilled hole with the tap shown in the hole size chart and the T-handle wrench supplied with the Thread Insert Repair Kit. Apply cutting fluid to the faucet cutting threads to produce clean threads in the aluminum while turning the T-handle wrench clockwise.
Step 5: how to fix aluminum thread
Turn the T-handle faucet wrench counterclockwise to remove the faucet from the now threaded hole.
Step 6: how to repair a thread
Thread a thread insert into the end of the installation tool supplied with your thread repair kit.
Step 7: aluminum threads
Place the end of the threaded insert into the threaded aluminum hole. Turn the installation tool clockwise to thread the insert into the hole. Stop rotating the installation tool when the threaded insert is flush with the top of the threaded hole.
Step 8: how to repair a damaged thread
Remove the installation tool from the installed thread insert. Slide a punch into the installed thread insert. Hit the back of the awl with a hammer to remove the pin from the bottom of the wire insert.
Warning: repair thread in aluminum
- Wear safety glasses when drilling damaged aluminum threads.
Items You’ll Need: How to repair damaged threads
- Thread Insert Repair Kit
- Set of drills
- 3/8 inch drill motor
- Cutting fluid