stripped thread fork drain plug

[bruce_launceston]

Follow the installation instructions and install the helicoil insert with a permanent loktite to stop it winding out next time.

[RSMike]

Repair postponed for now as luckily seems to be holding, did a short ride on a bumpy back road and no leaks yet.


I guess if I did tap up I would need a new plug with the same head size, as the area to seat the washer and head can't be any larger, maybe thats why helicoil is better?



I wonder if this kit is what I need?
http://tinyurl.com/br2wmmr


On the positive side, happy with the gaiters:

[georgesgiralt]

Yes, the Ebay thing is the good one. As the thread tool is tapered, you'll need a complete disassembly of the fork leg and a thorough cleaning afterwards.
Last but not least put a nylon tie to keep the screw on the leg. If during riding the pressure ask her to leave, she will get help from the tie ....

[RSMike]

Last but not least put a nylon tie to keep the screw on the leg. If during riding the pressure ask her to leave, she will get help from the tie ....

Nice idea George, thanks, I will do that.

[Luca]

Mike,

sounds like you are eventually going with the Heli-Coil, but it you decided to tap up a size and were worried about clearance around the head of the drain plug bolt you could probably use a socket-head (allen) bolt instead of a hex-head bolt.

And BTW, I like the gaiters.

[RSMike]

Yes, thanks, I ordered that helicoil kit today, I'll do a dry run first on a bit of scrap aluminium casting before I try it on the slider.

Though the allen head bolt is also a good idea that I had not considered.

The forks got a good test this evening, some confused car driver I was tailing couldn't decide which exit to take off a roundabout, so he slammed on the brakes midway between the two to consider a bit longer. First time I managed to lock the front wheel on the R65, It started to go sideways but I let go and it recovered, otherwise I was off,  , much profanities muttered in my helmet!
Anyway still no leaks, but I had George's zip tie in place so it might have helped.

[Rob Valdez 79 R65]

Glad to hear you have good brakes and tires!  Gotta watch out for fools!

[Justin B.]

Good on ya, Marc.

I'm up to my ass in landscaping projects and have had little time for the compuKer.

Wondered why it was so peaceful around here!  [smiley=ROTFLMAO.gif]

[montmil]

Good on ya, Marc.

I'm up to my ass in landscaping projects and have had little time for the compuKer.

Wondered why it was so peaceful around here!  [smiley=ROTFLMAO.gif]

Funny, Justin. If my fingers n' toes weren't so cramped up from all the dirt shoveling, I'd try to think up something witty...

However, I do have some plumbing chores that need attention and I hear that you are the Zen Master of the Pipe Wrench for all things waste drain. Wanta join for some fun?

[Rob Valdez 79 R65]

Good on ya, Marc.

I'm up to my ass in landscaping projects and have had little time for the compuKer.

Wondered why it was so peaceful around here!  [smiley=ROTFLMAO.gif]

Funny, Justin. If my fingers n' toes weren't so cramped up from all the dirt shoveling, I'd try to think up something witty...

However, I do have some plumbing chores that need attention and I hear that you are the Zen Master of the Pipe Wrench for all things waste drain. Wanta join for some fun?

Oh yeah - nothing like laying upside down on your back under a sink.  

[flatlander]

I have been searching for fork gators for my 82 R65 cafe conversion. Yours look great. Could you tell me whats size and where you got yours?

Thanks for your help

[livingdeadhead]

a few years ago a dealer did a repair to a thread with something called a 'time sert' , similar to a helicoil but solid and bonded in and much stronger than a helicoil, when i use helicoils i usually use a strong thread bond of some kind .
http://www.timesert.com/ here you go

[RSMike]

I have been searching for fork gators for my 82 R65 cafe conversion. Yours look great. Could you tell me whats size and where you got yours?

Thanks for your help

Thanks, I got them from Motobins in the UK, here is the link:

http://www.motobins.co.uk/displayfinal.php?q=93900&topsearch=1&go=GO

also don't forget to order 4 of these:
http://www.motobins.co.uk/displayfinal.php?q=60590&topsearch=1&go=GO

Mike

[RSMike]

a few years ago a dealer did a repair to a thread with something called a 'time sert' , similar to a helicoil but solid and bonded in and much stronger than a helicoil, when i use helicoils i usually use a strong thread bond of some kind .
http://www.timesert.com/ here you go

That looks good, I like the flange. But I already ordered the helicoil and did the job today.

Seems to have gone ok.

Some pics in case anyone has to do this job again:

(1) Drill and tap (M6 helicoil kit), with 5mm helicoils (I got from www.motorsport-tools.com)



(2) Tapped hole:


(3) Amazing amount of swarf to rinse out of the hole and slider (looks gold because its in oil):


(4) Helicoil inserted, be sure to go flush or just below surface. I did put some lock thread on the coil and leveled off rough spots on surface (not yet done in this photo).:


(5) Break off the tang that you used to insert the coil and retrieve from slider!


(6) I went with a copper crush that I felt had a better surface area


(7) And the thing I will not forget ever again!, Just snug with the drain washer.

[montmil]

Excellent work, Mike. Nicely played. Your post should help others whom experience these stripped aluminum thread issues. [smiley=thumbsup.gif]