Heli coil fix

If a heli coils ID threads were to big could you flux core weld it full and re- drill/tap it correctly? This would be for top right bolt (inside view) on fan pulley bracket 4.7 V8

 

I've welded holes in steel, and then redrilled and tapped before, but I've never done it on cast or engine parts

Post pics

 

So you'd be welding in a hole on the block so you could then re-drill and tap the hole to mount your fan pulley bracket? I'd honestly try drilling the hole in the bracket out to a larger size first and finding a bolt that matched the threads of the helicoil that you put in.

Otherwise, you'd be welding the hole shut, hoping you got decent penetration (assuming you're using a 125A flux core welder), grinding that flat, drilling through your weld (which will be harder than normal steel), then blind tapping the hole. I'd also be very concerned about drilling your hole perfectly straight, which will be hard to do while in the engine bay.

 

Did you check Timeserts to see if there is one that will accommodate a larger hole with smaller internal threads? (grasping at straws here...)

https://www.timesert.com/

 

Yes they exist. It’s called a Big Sert.

 

So is the aluminum bracket pulley bracket or the cast iron engine block that has a stripped hole?

 

I used a Big Sert to repair a damaged helicoil in a Porsche 944 rear control arm, cast aluminum. Worked great.

Before:


After:

 

Good question! He's not going to flux core weld to aluminum, not going to happen (and I would just suggest replacing the bracket if it was just the bracket). He could possibly do it if he had an aluminum spool gun and he wasn't dealing with a 7000 series aluminum.

 

I totally agree, but i’m not sure if the OP is referring to some sort of “as seen on TV” aluminum welding kit, or some youtube videos of a gang of indians welding up cast aluminum pistons in a clapped out excavator!

I’ve used a spool gun many times to fill in stripped out holes in various aluminum and parts. I’ve also used many different Timeserts in aluminum as well. If it is the engine block, then yeah, exactly what you said above about the trials and tribulations the OP will have if he tried to weld up the stripped hole in the block!