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Hey Dominik, Your right that you would have to drill out the hand brake ratchet plate if you put in anything larger than a 5/16" bolt which is why I don't want to change bolt size. Don't want to touch the handbrake lever assembly. I don't know about all of them, but the ratchet plates of original levers I had or repaired were mild steel. You could run a file across them and the would cut the material.
Nick, I think I know which route I am going to try. I normally like using a product called time-serts which have around the same wall thickness as a heli coil but is one solid piece instead of spun wire. It also has a shoulder stop. Unfortunately the hole is too large for this. I found a thin wall screw-in insert that will work. Only need to drill the bushings out to 25/32" and tap to 7/16" course thread. The bottom bushing is the one you have to watch since its OD is 5/8". The 1" OD of the upper bushing is not as delicate. Naturally my concern since I have to do it by hand and not on a drill press of mill is getting it 90 degress to plane surface. The main tubes also make it more ackward to work with the lower bushing. If this doesn't work them I am left with removing the existing bushings and machining up new ones and welding them to the chassis. Lets hope the inserts works.
AJ
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