I recently managed to partially strip a thread in an aluminium casting in a really awkward to get at place.

I won't be able to get at it to fit a helicoil without removing the whole engine and gearbox - and I really don't want to do that.

The bolt is one of many that holds the gearbox/bell housing together and also clamps a small fabricated aluminium bracket that holds the speed sensor, therefore the thread would not be highly stressed but I need to be able to slacken it off and re-tighten to adjust the sensor position.

So my question is - does a product exist such as a mastic or epoxy that I can inject, or cover the M10 bolt with, to create a new thread.

The short answer is no....sorry

Only suggestion I can come up with if there any thread left would be to fit a stud and put it in with some loctite 638 retainer.

Cheers
Davie

enough metal left to retap a bit bigger ?

may be able to do that without removing ?

It can probably live without it as structural bell-housing bolt until the engine is out so you could use Araldite or Loctite high strength grade bearing fit to glue it in.

As an alternative I had a not dissimilar problem with the retaining bolt for the speedo sensor on a Pug gearbox I used one of these 10x Plastic Honda Grille, Wheel Arch Lining, Splashguard &' Bumper Trim Clips | eBay
The intention was to fix it at a late date but surprisingly it worked for 4 + years until the car was crushed.

All good advice.

Thanks for your comments.

i would use some no nonsense metal to metal bond that comes in a music gun. the stuff is seems to work but does not set fully solid, very slightly rubberish.

Use a plasterboard fixing, the one with wings. A rawl plug will probably work as well.

[Edited on 19/3/13 by inkafone]

But and bolt it?

what you want is JBweld

I'd use a stud or 10mm threaded rod. Degrease the styd and hole then bond in with Chemical Metal, Belzona, JB Weld etc. Alternatively, could you find a Whitworth stud to fit? That would annoy any future folks working on the car...

Could you not use a longer bolt just a thread or 3 longer?