I made the mistake of buying chrome trim covers for the cam, sprocket, primary, and rocker box. I later thought they looked like crap, but they're a bitch to remove (a project for later).

Well, I later had an oil leak supposedly from my rocker box. I didn't torque the covers properly. Today I took my tools out with my new torque wrench. I got the specs (120-150) and decided to torque them only at 120 at first. I tested the torque wrench before hand and it worked properly. Torqued down all the bolts except one. The last one, however...was tightening down, then just started spinning.

I stripped my rocker box cover.

Great.

Just had to vent...again.

 

I suppose I'll need a new inner rocker cover, is this it?

http://www.harley-davidson.com/gma/g...bmLocale=en_US

 

Get a Tappet and pull It Out,,go to a Napa autoparts store and ask,,they will know.
Its easy just cover or seal off everything cause your gonna drill into the broken bolt.
Tape It up super good,,drill shavings will go every where.
the tappet is a reverse thread,,as It goes in and binds it will remove the broken bolt.
If you get the right size You won't damage the threads.....

 

120 inch pounds or foot pounds?
They make helicoils, which work very well if done right.
They can be stronger than stock.

I only use a torque wrench on a few things, crankshaft stuff and headbolts...


Brett

 

I seemingly stripped the threads inside the inner cover, not on the bolt itself.

 

Yes, the holes ALWAYS strip out first, mostly because its usually aluminum and the bolts are steel.

Helicoil.

Brett

 

Sounds like more than I can manage myself. I'd like an actual chrome set of rocker covers anyway, so I suppose it's all the more reason to upgrade.

Installing is going to be a bitch.

 

Ditto on the helicoil. This isn't a hard job, and it's one that you need to learn if you're gonna wrench on your own stuff. This won't be the last stripped threads you encounter.

 

I don't have any power tools (drills, etc) yet, and buying all that hardware (drill, bits, taps, helicoil) isn't something I can afford. I want to replace the covers anyway.

But I'm glad to hear about these things. It's certainly something I could put to use in the future.

Is it possible to put in a slightly longer bolt to grab some of the threads that haven't been stripped as a temporary solution, or is there nothing left to grab?

 

Depends.
Not a good idea as it wont go tight before it strips out the small amount of threads left (if any).

You can likely borrow a drill from someone, the helicoil kits sometimes come with a drill, a tap, the coils, and a tool to insert the coils.

Sometimes, if you work VERY carefully, you can tap it without drilling, but taps tend to snap easy.

Auto parts stores sometimes sell a little kit for under $20.00 with about 10 coils.
After 40 years, the rocker box studs on the old Triumph pulled out, I did the helicoil and green locktite (because they are studs) and they were much stronger than stock.

I would think buying a $20.00 kit and borrowing a drill (if needed) would cost a LOT less then a rocker box or cover plus gaskets!

On some things, in a pinch, you can tap to the next size up (even metric) and not helicoil, but that IS a bodge.


Brett