I've never had much luck using some of the traditional methods for repairing damaged threads in my projects.  For various reasons these techniques may not be workable solutions.  The thread may be too damaged to "clean up" by running the matching size and pitch tap through.  Drilling and tapping to the next larger size screw may not be an option for mechanical or aesthetic reasons.  Jamming in a screw of a different size or pitch or squeezing one of the thread "repair" compounds into the hole won't give you the fit and strength you might need.

My favorite option, by far, is to install a stainless steel insert into the hole that will give me EXACTLY the same size thread as the original, damaged thread.  I can the use precisely the same machine screw as I had used originally.  The inserts, tiny coils of stainless steel, can also be used right from the get go to add strong threads to parts made of softer materials like aluminum or even plastic.

I'll show you how to properly install one of these inserts in the main workshop at TechShop Detroit.  You buy a thread repair insert kit or use the basic tools available at TechShop.  In either case the drill press in the Metal Shop at TechShop is very useful for accurately drilling/enlarging the holes you need to make in your part to install these inserts.

Step 1: Gather the Tools

In the first photo you'll see my aluminum block with damaged thread.  The size of the threaded hole is (was) for a 10-32 machine screw and I'd like to keep it that way!

 Pictured below you'll see the kit of stuff you'll need to pull together to accomplish the repair.  This consists of:

-The stainless steel threaded insert, size 10-32
-A drill to enlarge the existing damaged hole
-The correctly sized tap to thread the hole to accept the threaded insert
-The special tool needed to install the insert (comes with the insert kit)
-A knock out bar to remove the tang on the insert after it is installed (more on that later)
-The part with damaged hole (but of course)
-The 10-32 screw I intend to use in the repaired hole and a screw driver to drive it in

And If I'm going to make a hole from scratch that I intend to install steel threads in from the very beginning:

-A center punch to mark my hole postion
-a hammer to give the punch a light, firm tap
<p>Very good project and well detailed.<br>But let me say my opinion from my experience.<br>Not need to buying a full set, of threaded insert / helicoil and the inserting tool, for any different size.<br>Using a bolt and a nut (the nut will be used as lock nut) can do the inserting job, with no extra cost. <br>The bold/nut must be at the same thread and pitch with threaded insert / helicoil.<br>Also the use of a Threadsealing glue is required to avoiding unscrewing of threaded insert / helicoil when need to unscrewed the bolt.<br>You can see how can use the bolt/nut trick here: https://www.instructables.com/id/DIY-Threaded-Insert-Helicoil-No-Lathe/step4/Where-I-have-use-this-Threaded-Insert/</p><p>Regards</p>
Good job on the presentation.I have been using these for over 15 years,they work great! They make these for putting metal threads into wood also,but I can't think of the name of them right now.I have used them alot,they work great for shelves,cabinets,desks and other things that you may want to take apart for moving(for those who move alot).Anyway,great job.
The inserts being used by Will Brick are called heli coils and the ones you're referring to, for wood, are threaded inserts. <br> <br>I wouldn't recommend using coils or inserts of dissimilar metals to your workpiece. Replace steel with steel, SS with SS, Al with Al... Look up Galvanic Corrosion, it's especially fun when you mix SS and Al. ;)
I agree completely,just thought I would mention it.
Very interesting. This method is used too to replace the thread in aluminum cilinders head of motors, where the spark plugs go. It is very effective. <br> <br>I didn't know there are many sizes of these replace threads.

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More by Will Brick:Quick Custom T-Slot Cleaner How To Repair Damaged Threads or Add Stainless Steel Threads to Any Project 
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