Quote:

what was your thread engagement? did the break occur at the end of the bolt?

How much depth was leftover after the end of the bolt threads?


I elected to use studs, since I was going for a solid roller to get as much thread engagement as possible in the aluminum.



I was using bolts that were more than full engagement of the heli-coil, but there really is nothing for the bolt to grip onto below the helicoil because the hole was drilled for the helicoil. I don't recall the coil bind spec, but I have checked that, and that is not the problem.
Anyhow, I'll fix it like I did the other side, mill it flat, install a 3/4" long Time-Sert, and add a spacer betwen the head and rocker hold down, and use the longest bolt that fits.

I may remove the other heli-coils and install the longer Time-Serts, but I'm not sure how hard it will be removing the heli-coils. I was thinking a reverse twist drill bit may do the trick?