From:Dave Hennessey e-mail:dave@toyhouse.org
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.

Dave

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


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Dave:
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.
:John
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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...

Dave

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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.

http://www.ccamca.org/timoniumShow.htm

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