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Originally Posted by unregistered
the BI holes are not that stout (thin brass)
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IMHO the brass sheet is strong enough to hold the radiator - the weak point is the self-tap threads through the brass. There
is room enough under the flange to put a nut. There
isn't enough room for your finger, but you can get an ignition wrench in there. Use scotch tape (or something like that) to hold the nut in the wrench or you're in for some frustration.
Of course, the only way for a nut under the flange to be useful is if you use short pieces of threaded rod and use nuts at the other end to actually fasten the BI to something.
The only time I've done this was to fix a BI Pro for a friend who really didn't understand how soft brass is (or as we used to say in the m/c shop I worked in long ago "Torque it down 'till it strips - then back off a quarter turn"
). Anyway, with a nut and fender washer under each flange it was
very solid (an issue because this was a lan party box - the reason my friend decided to torque those screws down).
So... the only failure I've seen was user induced (I'm sure BillA has seen a
lot more BI rads than me - maybe more than the rest of us combined). At the time I was thinking that the right answer (other than capture nuts) might have been for the mfgr to pre-thread the sheet and supply nylon screws. Better to have a 5 cent part fail.