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Minimum minor diameter for 1/4-20 is .196, or 4.978 mm, and max is .207", or 5.257 mm. Minimum minor diameter for 1/4-28 is .211", or 5.359 mm, max is .220", or 5.588 mm.
Rather than helicoils, could you fit M8 1 bolts?
Where is the head too big, diameter or depth?
Maybe I'm over thinking this.
This is quite possibly the case. What is the depth of thread engagement with the M6 screws?
The german guys use rivets with their kit. They have done 2 primary drives for me, I sent the drives to them for the job just for sure. http://www.fourever-classic-parts.de/index.php?option=com_content&view=article&id=26&Itemid=31
Cycle X is rebuilding these now also and then balancing them. May be worth calling Kenny and get his take on thread situation?
I agree, but then it ain't metric! Lol .....
What I meant was the length of the thread engagement? The more threads, the better.