help me repair these threads

[monster1]

I had to replace the o rings on the fuel cell of a fuel pump for my boat engine. Me being a *******, I overtightened the 10-32 screws and stripped out the threads on the aluminium fuel cell housing. I would say just fix it using heli-coils but the housing is so thin id run the risk of blowing out the walls of the cell. I think going to a 12-32 would risk the same. I've tried Jb welding the holes, drilling and tap but the screws still just pull out. Is there anything you guys recommend to repair these threads?

 

[OccupantRJ]

JBWeld a stud in place of using a bolt.

 

[Professur]

Steel thread insert

 

[KinzeMech]

Tap the hole the next size larger.

Also include pics.

 

[wornoutoldman]

Can you run a bolt through the backside thus making it a stud that can't be pulled out?

 

[trainer]

This stuff....I've had great luck with it. Clean everything with brake cleaner or acetone first. Unfortunately if you already have it gunked up with JB and you can't get all off, it probably won't work for you

 

[MP&C]

Closed end rivet nuts..

 

[monster1]

JBWeld a stud in place of using a bolt.

That is absolute genius and will work best in my situation! Thanks everyone for the ideas but this is the only one I feel will work fir my application due to not being able to drill any larger than 5/16". Id post pics to show you what I'm doing but unfortunately I can't post pics from my phone. Or can I?

 

[OccupantRJ]

Another item I have used to repair a worn bearing bore in the main frame of an industrial machine was Loctite stud and bearing mount. It was a do or die situation, so I went for it. Several years later, we rebuilt the machine, and the outer bearing race was so secure that it had to be ground with a diamond burr, and split to be removed.

 

[OccupantRJ]

That is absolute genius and will work best in my situation! Thanks everyone for the ideas but this is the only one I feel will work fir my application due to not being able to drill any larger than 5/16". Id post pics to show you what I'm doing but unfortunately I can't post pics from my phone. Or can I?

Thanks, but if you can get a few pics up, there may be other more permanent solutions available to you to use.

 

[eric_koski]

I have used this many times to repair stripped threads in aluminum housings. It Works!! http://media.midwayusa.com/pdf/instructions/Loctite_stripped_threads.pdf
You can find it in most auto parts stores and on Amazon .com