I have an 825 Mighty Demon that is about 10-11 years old. I was working on it this past weekend and one of the helicoils in the main body that the float bowl bolt threads into pulled out completely...along with the threads in the main body that were holding the helicoil in place.

Anyone have any suggestions on how to repair this? The hole right now is larger than 1/4". The way it looks I could use a 17/64" drill bit to clean it up but that puts me at a 1/4-20 helicoil. Going to a 1/4-20 bolt would require opening up the bolt hole in the metering block and float bowl. What a mess...

you could drill it out to a larger size, tap it and screw a threaded piece of aluminum in it and then drill and tap to proper size.

Despite its low use, the 2nd-hand Demon RS I bought some years back already had two BG-installed heli-coils pulling out of the main body. I tried to re-install the standard-size inserts, but they just pulled back out, too.

My solution was to go up in size to 6 mm x 1.0 mm tpi and even found some w/ a 5 mm allen-head style that still fit inside the float bowl screw head recesses, although I had to cut the screws down from the closest available length. This approach did require drilling the float bowl screw holes and the plastic washers just slightly oversize for the 6 mm screws, but the metering blocks didn't need anything to work w/ the larger screws.

So far, so good...

I had a Demon 750 Gold Claw years ago, it ran rich at idle, lean while driving, and about 5 of the bowl screws stripped out like they were made of butter.

I had thought about going with an M6 bolt but was hoping to keep them all the same. Timesert shows they have a bigsert that is designed to repair when a helicoil pulls out...but they don't show one for a 12-24...everything but that? I will contact them tomorrow to see if by chance they have one that will work.

BradH...do you remember where you got the M6 bolt you used?

I couldn't find an oversize insert for 12-24, either, which is why I went w/ the 6mm. The thread pitch is virtually the same (25.4 vs 24 tpi), so I figured the installation resistance would "feel" the same.

PM your address and I'll send you some. I have both 1.0 x 65 and 1.0 x 70, since I had to buy them in 10-packs each and wasn't sure which size to use. Although the 65 mm are slightly longer than Holley-spec screws, Demon screws are in between the 65 and 70. I ended up cutting down 70s w/ my repair, but you can have a couple of both to choose from.