oil drain plug stripped thread

[timtim]

I dont have any tread taps.Can i just remove oil pan,take to a machine shop and have em thread one size larger ?

[trapper]

I am sure you could.  However, as is the case with all of the 1st generation bikes I own, there is a raised rib around the oil drain hole, the purpose of which, i'm sure is to protect the bolt head in the event of a high center, or hitting road debris, etc.  The head of a larger bolt may not fit inside the rib or, if it does, not leave enough room to get a wrench or socket on it... unless you remove the rib...

[John Luttrell]

Take the pan to a machine shop and have a helicoil installed; then get a new standard plug for it.

[timtim]

Thanks guys.I failed to mention i have a '96.looks like alarger bolt wont work with that rib around the plug.to get a socket over it.havin a helicoil installed will save me a headache over tryin to find a used pan.any idea on the cost for a helicoil install?

[Charles S Otwell]

I don't really trust helicoils in oil pans especially aluminum. the aluminum is so much softer than the Helicoil that it is easy to strip the aluminum and then have the Helicoil come out with the plug.  I've always just used an oversized repair plug, most parts stores have self taping plugs just for stripped oil pans. Take your old plug with you and they should be able to fit you with the next size larger thread .Just my two cents.

[trapper]

Helical thread inserts work GREAT in aluminum; we use them all the time in my work.  There is a particular thread diameter to thread depth ratio that must be maintained, though.  The thread diameter of an oil drain hole is too large for the thin wall section of an oil pan.  There is just not enough wall section for a helical thread insert of this size to grab onto.  They MAY eventually come out in a thin wall such as this.

[surplusart]

I have several oil pans for 1st and 2nd gen bikes.....what year and make please?

[John Luttrell]

And Surplusart saves the day!  I'm a certified aircraft mech and have used helicoils in aluminum many times with no problems.  I believe a correctly installed helicoil would fix it; of course a new oil pan would be even better. 

[Charles S Otwell]

Sorry John didn't mean to step on your toes, I'm a retired multi-craft Mechanic and have had to patch plenty botched Helicoil jobs. My distrust of Helicoils is not unfounded, but Certified Aircraft Mechanic trumps multi craft mechanic, so I'll retract my opinion. Again sorry for butting in..

[John Luttrell]

Wait a minute Charles, by no means did I mean to belittle your opinion on the matter.  I too have seen many botched helicoil jobs where they were installed wrong or installed when they obviously were not a candidate for a repair.  This is why I suggested if he used a helicoil, to take the pan to a certified machine shop. 

LOL, like you, I am a "Retired" Mechanic, so we'll call it a draw and when we do meet sometime, the first round of soda water is on me.  Remember, it is all of our many skills and experiences "combined" that makes this board the treasure trove for bikers that it is.

[Charles S Otwell]

John my apology was sincere, I should have saved my opinion of Helicoils to a discussion about Helicoils and not challenged your suggestion. I could have offered my suggestion of a repair plug with out commenting on someone else's suggestion. The part about Certified Aircraft Mechanic trumping multicraft mechanic was meant light hearted, and should have been followed by smiley or something to convey that. My apology to timtim for interupting his thread. I'm looking for to meeting you and discussing Helicoils  ,  soda is on you ,pie is on me.

[John Luttrell]

MMMMMMMMM.............pie.

[Charles S Otwell]

Hey timtim let us know how everything works out and if you end up with another oil pan , don't get rid of the old one .I'll weld it up redrill and tap it and you have a good spare.

[timtim]

No apologies needed.Thanks guys for the opinions.Seems everyone agrees that helicores have somewhat of  a risk factor,especially for thin aluminum.I'm on a tight budget,so i think i'll try an oversized repair plug first.If the head is too big then i'll price out a replacement pan from surplusart.

[timtim]

Opps.just did a spelling check on my last posting.meant to say helicoil. helicore? whats that?