On Thu, 5 Mar 2009 09:04:59 -0800 (PST), wrote:

I have never had much luck in using Helicoil thread inserts - even
when I used a kit. Now I am trying to do so without buying a kit.

I am trying to install (1) 1/4-28 thread insert. Because of a
relatively thin wall condition, a thin wall solid thread insert is out
of the question (my prefered solution for thread inserts). About 15 -
20 years ago I aquired a strip of 1/28 thread inserts (brand unkbown).
So I figured that I would buy a 1/4-28 thrd insert tap from McMaster-
Carr and fumble thru getting the one thread installed (and have the
tap available to use in the future).

No luck in fumbling thru with it. I tried to twist the insert to
reduce the OD, I tried to deform the end of the insert to make it
undersize, I tried to install the insert backwards, I threaded the
insert on a short 1/4-28 SHCS to use as an install tool. Looking in
the McMaster catalog, I see that the installation tool for the 1/4-28
is a winder style to reduce the OD of the insert for $32+. For those
of you who use these regularily and know what you are doing - advice
please. Obviously, I am not overly interested in spending more money
to install one insert.
Find someone with the installer tool and pay them to install it.
Still cheaper than buying the tool, and it will be done right.
Or let the moths out of your wallet and buy the tool. Then you can
install the rest of those inserts for someone who doesn't have/need
the tool, and pay for it that way.