From:Dave Hennessey
Subject:McMaster-Carr (RE: RE: Gas Tank - Dash Mounting Holes) Date:Wed Jan 27 11:28:54 2010
Response to:2762
Probably everyone knows about McMaster-Carr already, but if you don't, it's a great place to find that hard-to-find anything.

For my dashboard / gas tank repair, I needed a bottoming helicoil tap, and 1/4 x 20 x 2 oval head stainless steel machine screws. Not only do they have them, but their web site makes shopping as easy as a McDonald's picture menu.

I built my order for the above and restocked my helicoil on their website Sunday night. Monday morning, I realized I forgot the countersunk tooth-lock washers, so I called them and they added the item to my order. Tuesday at 10am, UPS delivered the package at my home.

Fast, easy and convenient.


(P.S. I also got 2.5" long screws just in case)


Mine are 1/4-20 as well. Can't say if this is original or not. I had to Heili Coil one of mine too. Threads were still there but if I were to rely on them they would have stripped out.
Hey guys,

The threaded holes in the gas tank into which the dashboard screws go have stripped out on my KJ. Before attacking the tanks with drill and Heli-Coil, I was wondering if any one else has had this problem, and can give me any guidance on fixing them.

Q #1) What are the correct screws/threads?
Mine had 1/4 x 20 tpi x 2" flat-heads screws. Is 1/4 x 20 correct? Shouldn't they be oval heads?

Q #2) How deep are the threaded holes in the gas tank?
One is 1/2" deep, the other is ~7/16".

Q #3) How much meat is there in the "bosses"?
From looking through the filler hole, the bosses (probably not the correct term) seem to be pretty fat, but I couldn't get a reading on how deep they are. I really don't want to drill through into the gasoline section of the gas tanks.

Sorry for these pretty basic repair questions, but KJ tanks are pretty hard to find, and I really don't want to do anything I'll regret in the morning...



The AMCA Chesapeake Chapter is having their annual display at Timonium, MD on St. Valentine's weekend. This year's theme is four-cylinder motorcycles.

Even though it's freezing in my garage, I gotta get the bike ready for the show in the next two weeks.