"Joe Pfeiffer" wrote in message
"Karl Townsend" writes:

Saving the threads, even if it were possible is a waste
of time, because
the
treads have become aluminum oxide and have no residual
strength anyway.
Next time use anti-sieze at assembly. Most likely the
fault was
electrolysis, as they were probably diecast and zinc is
often alloyed with
the aluminum to promote flow in the mold. In the
presence of water, the
unit becomes thousands of little batteries.

On second inspection; if I can't get the bolts out, it
looks like drilling
the next size and tapping won't work. I'll have to make
all new. My version
will be a bit beefier. What's the best bolt for AL with
an eye on
electrolysis? AL bolts are too soft in small sizes. Is
stainless a good
choice? or maybe brass?

Won't work why? If it's because you can't go up a size,
I'll give a
hearty "me too" on the heli-coils.

Naw, heli-coils won't work. If the next larger size thread
is too much
then so is the o.d. of a h-c!
phil