stripped aluminum holes

Ok guys, for those of you who were at jasons on saturday, you alread know the situation, for those that werent i will bring you up to speed. The two holes on this used intercooler i got are stripped where the bov/bpv goes. Now everyone at jasons said i should try heli coils, but i cant seem to get them to work, so i retapped and threaded the existing holes from 8mm 1.25 thread to 10mm 1.50 thread, still strips it self out. any ideas? or should i just tell who i got it from i want my money back?

 

what about welding some aluminum nuts to it?

 

i dont weld, and wouldnt that make everything NOT flush with the intercooler?

 

I do. ya, that wouldn't work.

okay, what about an aluminum stud welded in the striped holes?

 

did the guy sell it to you with stripped holes?!?!

didnt you get it from a guy on here?

 

possibly, then retap the hole, but i dont want to uninstall this again, install to stock one, then try to reinstall again, this thing is such a pain to take in and out, i have so many band aids on my hands today from intstalling and uninstalling it yesterday

 

No, he didnt tell me they were stripped. Yea, i got it from 16gsx on here, i will call him later and see what he says, he told me when i bought it, if i didnt like it of if it didnt fit he would buy it back from me, so well see. Hes a good guy i dont think he would scam me.

 

drill the holes all the way through and put a nut on the other side (use longer bolts)

 

i could do that but would be next to impossible to install it with the bpv attached to the tmic before install, you either cant attach it to the stcok bpv tube or you cant get the turbo hose attached or the throttle body hose attached .

If i attach the bov after i install the intercooler, i dont know how i would get the nut around the back of the mount on either side, the opening is tiny.

 

What about drilling the holes out larger so they're clean and then helicoiling them or simply just tapping them?

 

we tryed a heatercoil already.lol
its too big.

 

aaaah gotcha sorry haha

 

how much room do you have to deal with here? is it possible to counter drill an area big enough so that you can put a nut in and haveit sit flush? is so you could JB Weld the nut on there and then use a matching bolt.

 

Yeah "heater coil".

 

i guess somthing like that might work.

 

damn idiots at checker.

 

Braze the holes shut, drill, and retap.

 

have someone weld an aftermarket BOV on, that way you wont need a different bov down the road, (for boost issues)

 

live near andover???

 

Josh, heli-coil the hole and do it right. Any welding done is basically permanent without a ton more work. The actual size is a 10mm X 1.25 pitch....not sure on the factory length of the bolts. I'll check the price of a heli coil kit for ya. edit: I can get you a kit from napa but their not cheap! $55.00

 

j/b weld some studs into the I/C itself, then use nuts instead of bolts!!!! wewt!!! or have the studs welded in! god damn im smart :lol: