Introduction
Stripped screw holes in aluminum, also known as oversized or over-tapped holes, can be a major headache when it comes to repairs. Fortunately, there are several ways to fix them, each with its own advantages and disadvantages. In this article, we’ll explore four common methods: using an aluminum repair putty, filling the hole with JB Weld, using a threaded insert, and applying epoxy glue. We’ll also discuss the pros and cons of each method so you can decide which one is best for your situation.
Using an Aluminum Repair Putty
An aluminum repair putty is a two-part epoxy-based compound specifically designed for repairing and rebuilding aluminum surfaces. It forms a strong, waterproof bond that can withstand temperatures up to 300°F (149°C).
Step-by-Step Instructions for Applying the Putty:
- Clean the area around the stripped screw hole with a wire brush or sandpaper.
- Mix the two parts of the putty according to the manufacturer’s instructions.
- Apply the putty to the stripped screw hole with a putty knife.
- Allow the putty to dry completely (usually 24 hours).
- Once the putty is dry, tap the hole with a tap and die set to restore the threading.
- Reinstall the screw.
Pros: The aluminum repair putty is easy to use and produces a strong, permanent bond. It’s also resistant to temperature fluctuations.
Cons: This method requires a tap and die set, which can be expensive and time-consuming to use.
Filling the Hole with JB Weld
JB Weld is a two-part epoxy-based adhesive that can be used to fill and seal stripped screw holes in aluminum. It forms a strong, waterproof bond that can withstand temperatures up to 500°F (260°C).
Step-by-Step Instructions for Applying JB Weld:
- Clean the area around the stripped screw hole with a wire brush or sandpaper.
- Mix the two parts of the JB Weld according to the manufacturer’s instructions.
- Apply the JB Weld to the stripped screw hole with a putty knife.
- Allow the JB Weld to dry completely (usually 8 hours).
- Once the JB Weld is dry, tap the hole with a tap and die set to restore the threading.
- Reinstall the screw.
Pros: JB Weld is easy to use and produces a strong, permanent bond. It’s also resistant to temperature fluctuations.
Cons: This method requires a tap and die set, which can be expensive and time-consuming to use.
Using a Threaded Insert
A threaded insert is a metal sleeve with internal threads that can be inserted into a stripped screw hole to re-establish the threading. It’s usually made of brass or stainless steel and is available in a variety of sizes.
Step-by-Step Instructions for Installing the Insert:
- Clean the area around the stripped screw hole with a wire brush or sandpaper.
- Drill out the stripped screw hole with a drill bit slightly larger than the threaded insert.
- Tap the hole with a tap and die set to restore the threading.
- Install the threaded insert into the hole with a hammer or press.
- Reinstall the screw.
Pros: The threaded insert is easy to install and produces a strong, permanent bond. It’s also resistant to temperature fluctuations.
Cons: This method requires a tap and die set and a drill bit, which can be expensive and time-consuming to use.
Applying Epoxy Glue
Epoxy glue is a two-part epoxy-based adhesive that can be used to fill and seal stripped screw holes in aluminum. It forms a strong, waterproof bond that can withstand temperatures up to 250°F (121°C).
Step-by-Step Instructions for Applying the Glue:
- Clean the area around the stripped screw hole with a wire brush or sandpaper.
- Mix the two parts of the epoxy glue according to the manufacturer’s instructions.
- Apply the epoxy glue to the stripped screw hole with a putty knife.
- Allow the epoxy glue to dry completely (usually 24 hours).
- Reinstall the screw.
Pros: Epoxy glue is easy to use and produces a strong, permanent bond. It’s also resistant to temperature fluctuations.
Cons: This method does not restore the threading of the hole and is not recommended for applications where the screw needs to be tightened regularly.
Drilling Out the Hole and Installing a Larger Screw
This method involves drilling out the stripped screw hole and installing a larger screw. It’s best suited for applications where the screw does not need to be tightened regularly.
Description of Drill Bits and Screws Needed:
- A drill bit slightly larger than the original screw.
- A screw slightly larger than the original.
Step-by-Step Instructions for Drilling and Installing a New Screw:
- Clean the area around the stripped screw hole with a wire brush or sandpaper.
- Drill out the stripped screw hole with the drill bit.
- Install the new screw into the hole.
Pros: This method is quick and easy to do and doesn’t require any special tools or materials.
Cons: This method does not restore the threading of the hole and may not be suitable for applications where the screw needs to be tightened regularly.
Conclusion
Stripped screw holes in aluminum can be a major headache when it comes to repairs. Fortunately, there are several ways to fix them, each with its own advantages and disadvantages. In this article, we explored four common methods: using an aluminum repair putty, filling the hole with JB Weld, using a threaded insert, and applying epoxy glue. We also discussed the pros and cons of each method so you can decide which one is best for your situation.
In general, the aluminum repair putty and JB Weld methods are best suited for applications where the screw needs to be tightened regularly. For applications where the screw does not need to be tightened regularly, the threaded insert and epoxy glue methods are more suitable. Finally, if you don’t have the tools or materials needed for the other methods, you can always try drilling out the hole and installing a larger screw.