Fuel Pressure Regulator Mod...
Thread Starter
Melting Slicks
Joined: Oct 2002
Posts: 3,193
Likes: 1
From: Cincinnati Oh
Fuel Pressure Regulator Mod...
Well, I've managed to strip the innards out of 3 of 6 of the size 6-40 torx bolts (try finding THOSE in the local hardware store). Nah, I didn't feel like ordering a box of 100 online somewhere to replace them, so I wound up tapping all six holes for size 8-32 allen head bolts of the same length (1/2" long) due to the ease of locating that size. I also was fearful of rounding out the torx bolt while REMOVING it, and creating a whole `nother problem of notching it with a dremel, etc.
Anyway, if anyone does this in the future, the pre-drilled holes are PLENTY deep to bottom your tap out in and yet leaving plenty of thread left for a replacement bolt of the same length but in the next larger 8-32 size. All in all, took about an hour to tap all six holes and get the FPR back in. Now I can cinch them down without worrying about rounding off that damn torx bit OR the bolt head (and without an inch-pounds torque wrench!). Also, I would recommend using small lock-washers to help prevent the bolts from loosening up (especially for you superram guys... what a PITA to get to).
Anyway, if anyone does this in the future, the pre-drilled holes are PLENTY deep to bottom your tap out in and yet leaving plenty of thread left for a replacement bolt of the same length but in the next larger 8-32 size. All in all, took about an hour to tap all six holes and get the FPR back in. Now I can cinch them down without worrying about rounding off that damn torx bit OR the bolt head (and without an inch-pounds torque wrench!). Also, I would recommend using small lock-washers to help prevent the bolts from loosening up (especially for you superram guys... what a PITA to get to).
Last edited by Ramanstud; May 14, 2006 at 11:57 AM.
Hard to find the damn security torx bit too..
Race Director
Joined: Jun 2004
Posts: 13,960
Likes: 707
From: WI
I've got mine apart to and was considering tapping them the same way. A pliers removed those ok, to reinstall them I plan to use a small chisel and knock the security pin out. I did check around local for new bolts of the same size, nothing, nor any tool to remove them. I have a few security bits but I have the next size bigger then I needed! 
Thread Starter
Melting Slicks
Joined: Oct 2002
Posts: 3,193
Likes: 1
From: Cincinnati Oh
here's a previous, related thread on the pitch sizes and Kid's source for those entertainingly obscure 6-40 x 1/2" bolts:
http://forums.corvetteforum.com/show....php?t=1372194
http://forums.corvetteforum.com/show....php?t=1372194
