Pelican IMS bearing stud has separated inside shaft

[black_box]

Yeah Mark, you're right. I should've filed it down first. I did punch it myself, and it seemed pretty centered, but I guess not. Helicoil is probably the best way to go now, although I am nervous about going all the way through with it. Having 9 out 16mm of the original hole should be safe and is a lot less scary than drilling completely through the case and possibly dropping metal chunks in.

I did try the screwdriver trick, BTW, no dice.

Real question to me: WTF happened to the original bolt? I checked the torque wrench against another one that has a indicator instead of a click (by pulling and redriving a random bolt in a metal door frame), and it was true to within 1 ft-lb at 8ft-lb's. So the bolt that pelican shipped me snapped with less than 8 ft-lb's??? That's crazy. I must be cursed on this job.

[2000boxster986]

Found these on the web... similar to helicoils. Might be just the ticket for your fix.
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[black_box]

Went ahead and helicoiled it for the original size threads, with what was left of the old bolt still stuck in there! I did some measurements, and it's not possible that the old bolt is protruding past the case, but to be safe I dropped a big dollop of JB Weld behind the helicoil to permanently fix the old bolt in place and anchor the helicoil (due to there not being any fixed stop behind it).

[2000boxster986]

Yay! Sounds like it's coming back together. Good deal!