On Sun, 3 Feb 2008 22:15:02 -0800 (PST), "
wrote:

The screws are stainless steel.

The load will be subject to intense vibration (its an intercooler
mounted on the front of a car) and weighs about 30lbs.

Use Helicoils of similar threded inserts.

Carl Boyd- Hide quoted text -

- Show quoted text -

let me clarify:

the fastener will go through a 1/8" thick steel bracket (unthreaded,
just a hole), and then will enter the threaded aluminum intercooler
wall, which is 3/16" thick.

the intercooler weighs 30 lbs, which makes all of this somewhat
critical i think, especially if the mounting fails, the intercooler
hits the freeway at 80mph pulling the rest of the engine with it...

is the 3/16" thickness of the aluminum too thin to do this?

How many of these bolts are you using?

Id say yes, its too thin by a considerable margin for a dynamic load
of 30lbs when vibration and G loading is included. The more bolts the
better.

weld on thickeners, at least 3/8"..many of them.

Gunner



"Pax Americana is a philosophy. Hardly an empire.
Making sure other people play nice and dont kill each other (and us)
off in job lots is hardly empire building, particularly when you give
them self determination under "play nice" rules.

Think of it as having your older brother knock the **** out of you
for torturing the cat." Gunner