Looking for some ideas.

I upgraded to a 01-style lower intake manifold from my 2000 type.
In doing so I traded my 2000 style Whipple mid-plate for a 2001 type.

When trying to fit the intercooler to the billet mid-plate it turns out 10 of the 11 threaded holes were stripped or were over tightened at some point before I got it. The Whipple manual states 96 inch pounds, the bolts started to spin at my first sequence of 40 inch pounds.

Any ideas on a fix, I am not keen on tapping the holes, as the next size up bolt is an M6, much bigger than the M5 that is there now. I doubt it would even fit.

 

Have it welded, redrill and tap it or use a heli coil.

 

You need to get a helicoil kit and use helicoil's in each of the stripped holes.

 

No matter what, you're going to be tapping it. I'd just drill and tap it to M6, and just open the holes up in the I/C core. At least then you'd have a more robust bolt in there as well.