Reply To: Material for threaded insert in aluminium

[HopperParticipant @hopper]

Then again, using stainless up against aluminium is not recommended practice either, due to galvanic corrosion. That is why stainless steel spokes when used with alloy rims come supplied with nickle plated brass nipples. Some say it's an old wives' tale but the rim and spoke manufacturers insist it is not. Not that it really matters for your application where you will never want to get the insert out again. It would work ok there. But stainless thread to stainless thread can gall and jam so I avoid it where possible.

I would use alloy 6061 etc or even just mild steel for your insert, make it top-hat shaped to ensure it cant slip out should the adhesive fail. And be sure to have the usual locknut/knurled collar in place on the adjuster as back up. It is what actually takes the load when done up even finger tight. (Bit like the top nut on double lock nuts that is endlessly debated!)

I have just been going through similar shenanigans making cables to fit a Norton Commando front brake into an Atlas front end. The later Commando uses UNF, the earlier Atlas CEI (cycle) thread. But the two models use different levers, one with adjuster, one sans. So cable lengths are all different too. Try buying a CEI threaded adjuster anywhere! And $80 plus international shipping for a cable from Venhill is not going to happen when I have a box full of useable cables and a lathe and a solder pot.

Edited By Hopper on 31/12/2022 02:41:59