Thanks for all the info. Alan - never too much info.! We use dowty washers rather than O rings and have never stripped a thread ourselves, these are on used rims we are trying to refurbish to get some decent MAG rims on a budget. I'll have a go with the 1D helicoils. I am a fan of helicoils in aluminium, in may microlighting days on critical locations ali threads were drilled out and helicoils inserted as technically the assembly is stronger than just ali. With the 1D being 5mm long this might just stick out either side of the rim material if it is less than 5mm thick. To you just fettle the helicoil down so it is flush (careful application of the dremmel!)
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