1936 VLD Fuel Tank to Frame thread repair

[NCriding]

All 5 of the threaded nubbins (2853-25) on my frame are badly beat. I placed a 10-32 timesert in one of holes to bring it back to size, then realized the mounting bolts (3532-18) are actually slightly larger, about 0.21" x 32, vs. the 0.193" x 32 of the timesert. I'm considering a couple options;

1. Find a 0.21 x 32 tap to hog out the timesert, like HD used when they made the frame - but no jobber like Grainger, Wurth, etc lists this size.
2. Use a die to narrow the bolts from 0.21 x 32 to 0.193 x 32, but I hate to weaken them and do this to the nice new cadmium hardware kit that is a replica of the originals . . .

Surely others have dealt with this - what have you done?
DSC02389.jpg

[Rubone]

The factory screws are 7/32 x 32. Taps are available. Not sure how you are going to deal with the timesert though.

[Steve Slocombe]

I think the factory screws are No.12 x 32 but a 7/32 x 32 tpi tap works. I have previously welded up the tank screw mounting holes and drilled and tapped them back to standard. Alternative is to use oversize screws. The Harley ones, still available nos, are 1/4 x 32 tpi, with the Colony replacements 1/4 x 28 tpi.

[Rollo]

Harbor Vintage carries replacement ones you weld or braze to the frame. I bought several of them a few years ago for one of the 36 VLH's I have.

Tom (Rollo) Hardy
AMCA #12766

[Robert Luland]

Go here and go to post #40
http://www.antiquemotorcycle.org/bbo...Prodject/page4

[NCriding]

Thanks to all! I'll try to find a 7/32 x 32 tap first and see what comes of it. I already have a bolt kit from Replicant metals that is identical to stock that I wanted to use, success with a 7/32 x 32 tap would allow that. If I'm not satisfied, maybe the oversize Colony bolt kit is the answer.
I was aware of the replacement nubbins from Harbor Vintage, but the stock ones are not that far gone to do that to the frame. I see those as a last resort.

[NCriding]

Finally got around to a satisfactory fix on this. I took the frame to a machinist/welder and asked him to Tig the holes, drill and re-tap. After he studied the challenge, he chose to re-tap with a very small pipe taper tap, install a stainless taper plug, then drill and re-tap to the correct 7/32 x 32. Looks pretty nice.
Tank nubbin2.jpgTank nubbin4.jpg