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Gil’s Mechanical Skills, Saved The Customer

Author: Gil Sher – A.M.I.A.M.E. – November 2025

When a Simple Bolt is a Big Problem

Recently a Volvo came into the workshop with what seemed like a typical faulty control arm issue.  But we quickly found that the control arm itself was actually in good nick. The culprit was the securing bolt.

As you can see in the images below, the bolt’s threads were seriously damaged. Unfortunately, the thread inside the bolt hole was also damaged. This is a tricky situation because you can’t just stick a new bolt in.  It wouldn’t hold, and it would just get damaged again right away.

It is quite easy to see the damaged threads on the bolt.  Just as the bolt was damaged so was the thread in the bolt hole.

The Cost of Waiting

Usually, when a bolt hole thread is gone, you have to replace the whole part it screws into. For this Volvo, the replacement parts weren’t available here in Australia. This meant a six week wait for the parts to be imported.

Not only is waiting six weeks a pain, but the estimated cost of that whole job would have been around $2,900. That’s a huge bill and a long time to be without your wheels.

Gil’s Clever Fix: Thread Repair

Instead of waiting and spending a fortune, Gil used his skills and the right tools to perform a 100% perfect repair. This fix involved installing a new thread insert into the existing bolt hole.

Here is the procedure we followed:

• Drilling Out the Damage: First, the damaged thread in the bolt hole was drilled out, which expanded the hole.
• Cutting the Seat: A reamer was then used to cut a small “rebate” or seat at the hole’s entry point. This rebate is key because it allows the shoulder on the new thread insert to sit completely flush with the surface.
• Inserting the New Thread: The insert was placed into the newly drilled hole using an adhesive to keep it securely in place. During the insertion, the insert expands, ensuring a tight fit against the enlarged hole.

• Final Securement: We then used a new, slightly larger diameter bolt with a thread that perfectly matched the new insert. This bolt secures the control arm correctly.

The Great Result

Thanks to Gil’s ingenuity, the customer got their Volvo back in just a few days. The total cost for this expert repair was only $618.

Plus, because this repair is so solid, we were able to provide a two year warranty. That’s the same great warranty they would have received on the brand new imported part, but without the six week wait or the massive price tag. It just goes to show that having the right skills and tools can save you a lot of time and money.

Gil has both the tools and skills to affect a 100% perfect result by doing the following procedure.