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Post Info TOPIC: Fitting a Helicoil to repair a stripped banjo bolt thread

Super Guru

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Fitting a Helicoil to repair a stripped banjo bolt thread

I had a couple of clutch covers that I had put to the back of the shelves as I couldn't figure how to repair it and the covers are too valuable to throw away.

The challenge is to drill the thread out for the Helicoil insert absolutely at 90 degrees.

This is the kit I used - not actually Helicoil but a copy:

Helicoil kit.jpeg

I enlisted the help of my brother to gain a few extra brain cells and we came up with a plan.

We removed the pressure relief valve and blanking plugs on the inside of the case to give a vertical face to which we screwed a squared off piece of wood to give us the right angle we needed.

Ready to Helicoil.jpeg

It was then possible to position the workpiece in the drill stand to drill the hole. Worked perfectly - phew!

Using the block of wood to position the clutch cover in the vice it was then an easy job to tap the hole and insert the Helicoil.

Helicoil fitted.jpeg

I made sure all the swarf was meticulously cleaned out of the holes and then put back the pressure relief valve and oilway blanking bolts.

Worked a treat!

Hope that may help someone now or in the futurewink


PS Sorry not to have taken more photos but we were really concentrating to get it right! Hope the explanation makes sense.


Exeter, Devon, UK

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