Thread repair using a helicoil kit.

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Whenever someone strips a thread on something, usually in soft aluminium it can feel like the end of the world, sometimes the manufacturer is blamed for not making a more durable product, sometimes the blame falls on the person who worked on it last, usually a dealer or repair shop, whatever the previous history one is usually confronted with the tell tale sign of the bolt which won't torque up, the spark plug which either won't screw in or doesn't tighten, the oil drain plug which won't tighten either sometimes with the evidence of metal swarf of what was once the thread, another tell tale is the casing screw which suddenly makes a loud crack when its finally tightened suddenly becoming one which won't tighten at all, what's there to do? go & pull your hair out, throw things at the cat, make a strong cup of coffee &c, the important thing is to take stock of what's happened knowing that it's not your fault & start doing your homework on how to fix it.
Years ago Helicoiling was mainly the preserve of engineering companies & repair shops, that's because the kits were horrendously expensive, times having changed & along came the world wide web & ebay, single sized kits have now become very affordable & for most applications they are just the ticket as well as a godsend, the important considerations are the ability to drill a hole & tap a thread correctly plus to read & study the kit makers instructions & or watch the videos on youtube.
Assuming you have the required skills to drill & thread  hole correctly which must also be straight, the first thing is to correctly identify the thread which either the bolt or component fits into, if the thread is completely stripped out, the remaining hole should be no larger than the original bolt or component, using a correctly fitting tap wrench & having lubricated the tap, simply tap out the hole checking that it's going in straight using a ruler or set square, having tapped the hole, clean out the hole with an air line then measure the depth of the hole as inserts do come in varying lengths & give you a lot of personal satisfaction when the inset you've just fitted goes almost right to the bottom of the hole taking into account the taper on the end of the tap.

Most kits use a simple slotted insertion tool, fine thread kits come with a prewinder insertion tool, whatever type of kit you have, it is important to read the instructions first, spark plug kits come with a piloted reamer tap which simplifies the drilling & re-threading processes altogether, good luck & happy re-threading=JD.
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