I need some sort of threaded insert to put into my 2 x 4 x .188 frame to take a 3/8" bolt. I would prefer to not have to put a window in the frame rail and weld a nut inside. There must be some trick threaded insert out there. Any ideas?
Make a threaded weld bung. Use 3/4" round cold rolled - hot rolled also works - thread it 3/8-16, put a shallow angled chamfer on it for the weld bead, drill the frame for 3/4" or whatever. That size frame hole is usually the right size to grab the 3/4" OD weld bung and hold it flush with the outer surface of the frame. TIG or MIG it on and you end up with the upper surface flush with the frame. If you're adding some threaded pieces for seat belts or roll bars, use 2" diameter stock and machine a 1" diameter step in them. You'll have to machine or grind a flat on each side, bout 1/8" or so and round the upper edges so this larger weld bung can fit inside a boxed frame. Install the stepped bung from underneath and weld it in from the top. The weld, the step and the larger size make a threaded bung that won't pull through the frame. Drill the frame 1" (for the 7/16 or 1/2" threaded stepped bung) If you can weld close enough, you can knock a 3/8-16 nut - plain, no cad or iriditing on it - round in a drill press with a threaded mandrel and a file. Take it easy on the side pressures as drill presses are not designed for side loads. That's the easy way to make threaded weld bungs. Far as holding them in place if they're a loose fit, screw a washered bolt in and shim it in place with a couple of small blocks. Tack weld, remove bolts and shims and finish weld.
[ QUOTE ] http://www.pd.infn.it/~morandin/lstprod/threaded_inserts.pdf Threadserts - handy kit to have... Mutt [/ QUOTE ] Perfect solution. Man... MSC Direct has such cool stuff...
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