Dodge Brass Inserts

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Fastening Solutions for Plastics
At
Emhart
, creating the future is about growth, about change and about taking risks.
It is who we are and what we do. Our focus is to reduce the overall product assembly costs of our
customers by anticipating needs and meeting those needs with technology and market-driven
solutions.
Emhart is a global leader in the design and creation of unique assembly technologies, delivering depth
and breadth of service and product through a flexible, cross-functional global organization.
Owning The Customers Total Experience
We provide every customer with the capability to satisfy every aspect of fastening and assembly
technology. From concept through installation, around the corner and around the globe, Emhart
Technology Optimization
Emhart has the ability to objectively match customer priorities, applications and manufacturing
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Creating the Future Worldwide.
develops and delivers solutions for challenging assembly applications.
environment with the most appropriate assembly technology and fastening systems. We provide this
capability through Application Engineers, and Mobile, Stationary and Virtual Innovation Centers located
around the world. Each is electronically linked, capable of sharing application data and new design
concepts with each other as well as with our customers.
System Integration
Emhart provides technological solutions in over 100 different countries. For each of these countries and
for every application, we deliver innovative, integrated systems solutions from concept and design
through system integration, worldwide.
Product Consultancy
Emhart employs Application Analysis and Value Engineering to demonstrate how our technology can
enhance the assembly process, and Value Analysis to detail the cost/benefit relationship of applying
our technologies.
Innovative Services
Emhart is infused with the spirit and culture of innovation. From our Stationary Innovation Centers to
our unique Mobile Innovation Centers, Emhart
has built a worldwide service and technology
infrastructure to support our customers,
24 hours a day, seven days a week.
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DODGE GRIPCO HELI- COIL NPR PARKER- KALON POP TUCKER WARREN
Insert s
Fastening Solutions for Plastics
Dodge
inserts for plastics are widely recognized and highly regarded products in
the fastening market. Since the 1950s, Dodge has been identified as the leader in its industry
which can largely be attributed to its focus on providing high quality products.
DODGE Products are available in various types and styles to suit almost any insert application in
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plastic. DODGE inserts are designed to provide the high performance strength values of molded-in
inserts while still retaining all of the economical advantages of insert installation after molding. In
addition to the standard products, DODGE has also developed insert types and styles for specific
applications.
DODGE Sales Engineers have broad experience in insert technology and are available to provide
on-the-spot answers to any of your technical questions. Our highly trained Applications
Engineering staff in Danbury, Connecticut will be glad to furnish technical assistance, compile test
data, prepare samples for your evaluation and make specific recommendations on insert designs,
installations and assembly systems. Our fastening experience and expertise is available for
designing special inserts for unique or critical applications. Designs such as studs, mold-in
inserts, and compression limiters have been developed and supplied by DODGE.
DODGE products are manufactured to the same exacting quality systems required by the military,
aerospace and automotive standards. The Danbury manufacturing facility has been certified ISO
9001, QS 9000 and ISO 14001. We are committed to an ongoing and never ending process of
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quality improvement and total customer satisfaction.
Insert Selection Guide
Page
Ultrasert I
Ultrasert II & Ultrasert II Screw-Lock
Ultrasert III
14 & 15
Designed for high volume production

Can be installed ultrasonically, with heat, or molded in
Symmetrical design eliminates orientation before installation
Ideal for automated installation feeders
Lead-in pilots at both ends assure accurate positioning prior to installation
Opposing diagonal knurls provide torque resistance
Undercuts provide tensile strength
Ultrasert IV
10 13
Most widely accepted and used

Tapered for easy heat or ultrasonic installation
Diagonal knurls for optimum torque resistance
Undercuts for superior tensile strength
Screw-Lock has unique locking element for vibration applications
Eliminates need for plastic pellets or patches on screws
Ideal for adjusting screw applications
Avaliable in two lengths for design flexibility; Screw-Lock in long length only
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8&9
Fluted for ultrasonic or heat installation

Tapered for accurate positioning prior to installation
Vertical flutes provide high torque resistance
Stepped inclined ribs provide optimum tensile strength
Gradual external taper optimizes flow of plastic for rapid and smooth installation
16 & 17
Designed for installation in straight holes

Lead-in pilot at end assures accurate positioning prior to installation
Opposing diagonal knurls provide excellent torque resistance
Undercuts provide tensile strength
Ultrasert IV Flange
18 & 19
Same as Ultrasert IV but with flange on the knurled end

Flange provides a large bearing surface, an advantage in weaker plastics
Provides high strength when used in a reverse screw entry where the load is taken up by
the flange, i.e. screw entry opposite flange end
Ideal for use as electrical contact or fastening terminal connectors
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Ultraseal
20
Provides positive seal between insert and parent material for use in pressure applications
utilizing high temperature O-ring
Eliminates the need to mold or machine threads
Easily installs with heat
Available in 1/8, 1/4, and 3/8 NPTF threads
Ultra-Mold
21
Revolutionary two-piece design allows full thread engagement without the need for extra space
Controlled minor diameter reduces insert movement during molding assuring accurate
alignment
Unique counterbore accurately positions insert over molding pin and allows for easy bolt entry
during assembly
No machining chips to contaminate final product
Can also be installed using heat
Emhart Teknologies Shelton, CT Tel. (203) 924-9341 Fax (203) 778-8409
C E R T I F I E D
ISO9001QS9000
Insert Selection Guide
Page
22
Miniature Inserts
23
Compression Limiters
Available in two styles to accommodate various applications

Symmetrical style is designed for high volume production, no special orientation required saving
time and lowering overall cost
Flanged style provides larger bearing surface which is ideal for electrical contact and provides
high strength in reverse screw entry application
Either style can be installed with heat
Standard Expansion
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24 & 25
Non-threaded bushing to take bolt load instead of the part

Eliminates bending or cracking of plastic part due to tightening of bolt
Custom designed for each application
Can be installed with heat or ultrasonics or by pressing in
Installs without heat or ultrasonics

Easy to install, two piece insert for use in blind holes in thermoset or thermoplastic materials
Depressing the captivated spreader plate expands the knurled portion, permanently anchoring
the insert
Can be installed protruding above the surface for use as a locating device
26 & 27 Flanged & Clinch Expansion
Flanged insert is ideal for electrical contact or fastening terminal connections

Can also be used to join mating parts by inserting through mating part and into receiving hole of parent material
Clinch insert is same as the Flanged insert but can be clined over a terminal connector for electrical
contact
Used extensively in electrical industry
Simultaneous installation and clinching operation using simple press-type tool
Both styles are excellent for use in thin-section applications since flange absorbs much of the installation force
Both styles install by depressing the captive spreader plate which expands the knurled portion, permanently anchoring the insert
28 & 29 Self Threading & Flanged Self Threading
6&7
31
32
33
C E R T I F I E D
ISO9001QS9000
Spred-Lok
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30
Internally and externally threaded with two slots which provide cutting edges similar to a tap
Insert cuts its own thread when driven into a cored or drilled hole
Friction between insert and plastic permanently anchors the insert
Can be installed with a tap wrench or drill press with tapping head
Available with or without a flange
One-piece insert with unique, slotted, expandable outside diameter

Can be installed in thermoset or thermoplastic materials
No special tooling required simply press in
Mating screw expands the insert locking it in place
Use in blind or through holes
Available with or without a flange
Additional Information
Pages
Capabilities
R&D and Assortment Kits
Troubleshooting Guide
Testing Terminology
34
35
36 & 37
38 & 39
Typical Applications
Custom Capabilities Guide
Jack Nut Threaded Inserts
Well-Nut Threaded Inserts
Dodge Capabilities
Design &
Engineering
Support
Development support
includes
Conceptual ideas
Preliminary designs
and drawings
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Value Engineering
Product
Development
Customer Service
Dedicated and caring people trained on

sophisticated computerized equipment to ensure
Pre-production samples
and engineering prototypes
are produced on state-ofthe-art CNC equipment.
Prompt pricing and accurate delivery information

Work in progress status
J.I.T. scheduling
New products are

thoroughly tested
before leaving our
facility.
Production
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150,000 square foot

manufacturing
facility.
Quality
ISO 9001 & QS 9000 Certified

Lot control ensuring product traceability.
Statistically controlled manufacturing processes.
Material certification.
All products manufactured in the U.S.A.
Dedicated to
delivering high
quality products on
time.
Unique machining
techniques allow us
to be more versatile
and efficient.
Utilize the best
machining materials
available which meet
stringent internal
specifications.
Products controlled through MRP systems to
ensure on-time delivery.
In-House tooling capabilities.
C E R T I F I E D
ISO9001QS9000
Dodge Capabilities
Technical
Seminars
Formal technical seminars
offered to engineering,
manufacturing, purchasing
and quality personnel.
Inventory
Dodge has over 50 factory-trained sales

engineers located throughout North America.
We provide extensive knowledge and expertise in
insert technology.
Sales engineers will conduct on-site engineering
seminars to ensure that your group is aware of the
latest developments in plastic fastening technology.
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Instructors include
representatives from our
marketing and engineering
departments.
Factory Trained
Sales & Applications
Engineers
An extensive inventory is
managed for both
standard and custom
inserts.
State-of-the-art packaging
equipment guarantees
that box quantities are
exact and finished goods
are routed to the
warehouse to facilitate
just-in-time delivery.
Broad range of inventory

is conveniently located
throughout North America.
Insert
Cleaning
Applications engineers are ready to evaluate and

recommend insert designs and installation methods.
They also furnish samples, conduct product testing
and compile test data.
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Special cleaning
systems ensure
maximum cleanliness
of our inserts.
Cleaning process
eliminates brass chips
or oil that may contaminate or damage an
entire system.
Adhesive grid may be
added to the shipping
container to trap any
loose particles created by handling
or transportation.
C E R T I F I E D
ISO9001QS9000
Ultrasert I
Vertical flutes and horizontal fins provide superior assembly strength

Tapered design assures rapid and accurate alignment prior to installation
Flute and fin design provides a chip-free environment
Ultrasert I
The Ultrasert I insert is a fluted brass insert designed for ultrasonic or heat installation into thermoplastics. The tapered design allows for accurate positioning in the receiving hole ensuring proper alignment prior to installation. The vertical flutes provide resistance to rotation and the stepped inclined ribs are for
tensile strength. The gradual external taper optimizes the flow

of plastic as the insert/plastic interfaces, permitting a smooth
and rapid installation.
MIN. BOSS DIA.

8
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MIN. DEPTH =
INSERT LENGTH
PLUS .030 INCH
(0.77 mm)
INCH INSERT SPECIFICATIONS
HOLE SIZE RECOMMENDATIONS
Thread Size
Part Number
Diameter
A
B
.005
.005
4-40
6-32
8-32
10-24
10-32
1/4-20
1/4-28
70815-04-250
70815-06-312
70815-2-375
70815-3-438
70811-3-438
70815-4-562
70811-4-562
.173
.219
.252
.297
.297
.383
.383
Diameter
C
D
.001
.001
.250
.312
.375
.438
.438
.562
.562
.141
.179
.206
.243
.243
.320
.320
.154
.198
.227
.268
.268
.350
.350
Minimum
Boss Diameter
.346
.438
.504
.594
.594
.766
.766
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.145
.183
.212
.249
.249
.323
.323
Length
L
.004
METRIC INSERT SPECIFICATIONS
Thread Size
Part Number
M3x0.5
M3.5x0.6
M4x0.7
M5x0.8
M6x1
70817-3-079
70817-3.5-079
70817-4-095
70817-5-111
70817-6-143
Diameter
A
B
0.13
0.13
5.51
5.51
6.35
7.49
9.68
4.65
4.65
5.38
6.32
8.20
Length
L
0.10
Diameter
C
D
0.03
0.03
7.92
7.92
9.53
11.13
14.27
4.55
4.55
5.23
6.17
8.13
5.03
5.03
5.77
6.81
8.89
Minimum
Boss Diameter
11.02
11.02
12.70
14.98
19.35
C E R T I F I E D
ISO9001QS9000
Ultrasert I Test Data
ABS
POLYCARBONATE
STRUCTURAL FOAM
NYLON 6/6 30% G.F.
Tensile
lbs
Rotation
lbin.
Tensile
lbs
Rotation
lbin.
Tensile
lbs
Rotation
lbin.
Tensile
lbs
14
26
42
62
104
251
309
466
715
1130
22
42
81
115
202
374
453
843
1245
1820
23
44
70
116
206
229
441
660
1005
1802
23
44
84
148
225
295
416
653
874
1434
STRUCTURAL FOAM
NYLON 6/6 30% G.F.
Metric
Rotation
Nm
Tensile
N
Rotation
Nm
Tensile
N
Rotation
Nm
Tensile
N
Rotation
Nm
Tensile
N
M3
M3.5
M4
M5
M6
2.94
2.94
4.75
7.01
11.75
1375
1375
2073
3180
5026
4.75
4.75
9.15
12.99
22.82
2015
2015
3750
5538
8096
5.20
5.20
7.91
13.11
23.27
1962
1962
2936
4470
8016
4.97
4.97
9.49
16.72
25.42
1850
1850
2905
3888
6316
No. 4
No. 6
No. 8
No. 10
1/4"
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Rotation
lbin.
Inch
ABS
Screw failed
POLYCARBONATE
Ultraserts
Dodge Ultraserts can be installed using ultrasonic equipment
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NOTE
The test data should be considered

as average values for the general
families of plastics indicated. Critical application requirements may
necessitate further specific testing.
(moderate to high production) or thermal installation equipment

(prototype work and low quantity production). Thermal equipment can be as simple as a soldering iron held by hand or
mounted in an arbor or drill press. More refined equipment is
available with adjustments and settings for precise uniform installations.
The plastic material failed in all

cases except where noted.
C E R T I F I E D
ISO9001QS9000
Ultrasert II
Installed ultrasonically or with heat

Two lengths to choose from allowing design flexibility
Diagonal knurls & undercuts provide superior assembly strength
Excellent design for automated systems
Long
L
Insert
Specifications
0-80, 2-56,
M2 and M2.2
Ultrasert II have a
single diamond
knurl.
MIN. BOSS DIA.
Short
MIN. DEPTH =
INSERT LENGTH
PLUS .030 INCH
(0.77 mm)
0-80
0-80
2-56
2-56
4-40
4-40
6-32
6-32
8-32
8-32
10-24
10-24
10-32
10-32
1/4-20
1/4-20
1/4-28
1/4-28
5/16-18
5/16-18
5/16-24
5/16-24
3/8-16
3/8-16
3/8-24
3/8-24
Diameter
A
B
.005
.004
Length
L
.004
Part Number
6041-0BR115
6041-0BR188
6035-02BR115
6035-02BR188
6035-04BR135
6035-04BR219
6035-06BR150
6035-06BR250
6035-2BR185
6035-2BR312
6035-3BR225
6035-3BR375
6041-3BR225
6041-3BR375
6035-4BR300
6035-4BR500
6041-4BR300
6041-4BR500
6035-5BR335
6035-5BR562
6041-5BR335
6041-5BR562
6035-6BR375
6035-6BR625
6041-6BR375
6041-6BR625
.141
.141
.141
.141
.172
.172
.219
.219
.250
.250
.297
.297
.297
.297
.375
.375
.375
.375
.469
.469
.469
.469
.563
.563
.563
.563
.123
.112
.123
.112
.157
.146
.203
.190
.230
.213
.272
.251
.272
.251
.354
.332
.354
.332
.439
.406
.439
.406
.532
.493
.532
.493
.115
.188
.115
.188
.135
.219
.150
.250
.185
.312
.225
.375
.225
.375
.300
.500
.300
.500
.335
.562
.335
.562
.375
.625
.375
.625
M2x0.4
M2x0.4
M2.2x0.45
M2.2x0.45
M2.5x0.45
M2.5x0.45
M3x0.5
M3x0.5
M3.5x0.6
M3.5x0.6
M4x0.7
M4x0.7
M5x0.8
M5x0.8
M6x1
M6x1
M8x1.25
M8x1.25
M10x1.5
M10x1.5
10
Part Number
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Internal
Thread Size
Diameter
C
D
.001
.001
Minimum
Boss
Diameter
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Internal
Thread Size
6075-2BR029
6075-2BR048
6075-2.2BR029
6075-2.2BR048
6075-2.5BR034
6075-2.5BR056
6075-3BR038
6075-3BR064
6075-3.5BR038
6075-3.5BR064
6075-4BR047
6075-4BR079
6075-5BR067
6075-5BR111
6075-6BR076
6075-6BR127
6075-8BR085
6075-8BR143
6075-10BR095
6075-10BR159
.129
.123
.129
.123
.163
.159
.209
.206
.236
.234
.278
.277
.278
.277
.363
.363
.363
.363
.448
.448
.448
.448
.540
.540
.540
.540
.282
.282
.282
.282
.344
.344
.438
.438
.500
.500
.594
.594
.594
.594
.750
.750
.750
.750
.938
.938
.938
.938
1.126
1.126
1.126
1.126
Diameter (mm)
A
B
0.13
0.10
3.58
3.58
3.58
3.58
4.37
4.37
5.56
5.56
5.56
5.56
6.35
6.35
8.33
8.33
9.53
9.53
11.91
11.91
14.30
14.30
.118
.107
.118
.107
.153
.141
.199
.185
.226
.208
.267
.246
.267
.246
.349
.321
.349
.321
.431
.401
.431
.401
.523
.488
.523
.488
3.12
2.84
3.12
2.84
3.99
3.71
5.16
4.83
5.16
4.83
5.84
5.41
7.82
7.19
8.99
8.43
11.15
10.31
13.51
12.52
Length (mm)
L
0.10
2.9
4.8
2.9
4.8
3.4
5.6
3.8
6.4
3.8
6.4
4.7
7.9
6.7
11.1
7.6
12.7
8.5
14.3
9.5
15.9
Diameter (mm)
C
D
.03
.03
3.00
2.72
3.00
2.72
3.89
3.58
5.05
4.70
5.05
4.70
5.74
5.28
7.70
7.06
8.86
8.15
10.95
10.19
13.28
12.40
3.27
3.12
3.27
3.12
4.14
4.04
5.31
5.23
5.31
5.23
5.99
5.94
8.00
8.00
9.22
9.22
11.38
11.38
13.71
13.71
Minimum
Boss
Diameter (mm)
7.16
7.16
7.16
7.16
8.74
8.74
11.13
11.13
11.13
11.13
12.70
12.70
16.66
16.66
19.06
19.06
23.83
23.83
28.60
28.60
C E R T I F I E D
ISO9001QS9000
Ultrasert II Test Data

ABS
Length
In.
Inch
No. 0
.115
.188
.115
.188
.135
.219
.150
.250
.185
.312
.225
.375
.300
.500
.335
.562
.375
.625
No. 2
No. 4
No. 6
No. 8
No. 10
5/16"
3/8"
50
65
67.5
81
ozin.
ozin.
ozin.
ozin.
13
17
23
25
37
45
51
68
102
116
155
214
220
229
Tensile
lbs
Rotation
lbin.
Tensile
lbs
79
162
79
162
147
258
220
370
304
469
448
726
700
1157
739
1435
940
1743
52 ozin.
70 ozin.
110 ozin.
168 ozin.
20*
23*
33*
45*
52*
88*
86*
125*
157
231
259**
345**
383
520
135
258
135
258
230
417
341
661
538
910
773
1388
1283
2073
1555
3128
2065
3638
ABS
Metric
M2
M2.2
M2.5
M3 & M3.5
M4
M5
M6
M8
M10
52
70
90
93
ozin.
ozin.
ozin.
ozin.
19
24
29
31
32
50
55
72
123
131
167
196
246
297
Tensile
lbs
Rotation
lbin.
97
224
97
224
187
393
236
487
304
512
505
801
769
1171
932
1767
1356
2100
58
65
58
65
ozin.
ozin.
ozin.
ozin.
20
21
33
34
60
66
70
133
132
220
304
428
420
518
POLYCARBONATE
STRUCTURAL FOAM
Tensile
lbs
96
198
96
198
211
330
286
509
355
883
565
1310
973
1884
1506
2654
2040
3303
NYLON 6/6 30% G.F.
Rotation
Nm
Tensile
N
Rotation
Nm
Tensile
N
Rotation
Nm
Tensile
N
Rotation
Nm
Tensile
N
2.9
4.8
2.9
4.8
3.4
5.6
3.8
6.4
4.7
7.9
6.7
11.1
7.6
12.7
8.5
14.3
9.5
15.9
.48
.57
.48
.57
1.47
1.92
2.60
2.82
4.18
5.08
6.78
8.81
11.52
13.11
17.51
24.18
24.90
25.90
351
721
351
721
654
1148
979
1646
1352
2086
2260
3599
3114
5147
3287
6383
4181
7753
.78
1.19
.78
1.19
2.26*
2.60*
3.73*
5.08
5.88
9.94*
10.85
15.82
17.74
26.10
29.26
38.98
43.30
58.80
601
1148
601
1148
1023
1855
1517
2940
2393
4048
4168
6761
5707
9221
6917
13914
9186
16183
.63
.66
.63
.66
2.23
2.75
3.35
3.54
3.56
5.65
6.25
8.08
13.84
14.80
18.81
22.10
27.80
33.60
429
995
429
995
834
1748
1048
2164
1350
2279
2723
3903
3421
5208
4146
7860
6032
9341
.90
.90
.90
.90
2.26
2.37
3.73
3.84
6.78
7.46
13.55
19.54
14.91
24.86
34.35
48.36
47.45
58.53
427
881
427
881
939
1468
1272
2264
1579
3928
3777
7037
4328
8380
6699
11806
9074
14692
Screw failed
Ultraserts
sa
l
NOTE

C E R T I F I E D
Rotation
lbin.
NYLON 6/6 30% G.F.
Length
mm
*Internal thread stripped
ISO9001QS9000
STRUCTURAL FOAM
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1/4"
Rotation
lbin.
POLYCARBONATE

11
Ultrasert II Screw-Lock
Unique internal locking element

Locks screws in place
Diagonal knurls and undercuts provide
superior assembly strength
Ultrasert II Screw-Lock
The Screw-Lock Ultrasert II is designed for use in vibration appli- cycles. Screw-Locking Ultrasert II inserts can be installed
cations or where periodic screw adjustment is required. It fea- with either ultrasonics or heat.
tures a unique internal locking element that is reusable for many
MIN. BOSS DIA.
8
L
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MIN. DEPTH =
INSERT LENGTH
PLUS .030 INCH
(0.77 mm)
4-40
6-32
8-32
10-24
10-32
1/4-20
1/4-28
Part Number
Diameter
A
B
.005
.004
Length
L
.004
Diameter
C
D
.001
.001
6035L-04BR219
6035L-06BR250
6035L-2BR312
6035L-3BR375
6041L-3BR375
6035L-4BR500
6041L-4BR500
.172
.219
.250
.297
.297
.375
.375
.219
.250
.312
.375
.375
.500
.500
.141
.185
.208
.246
.246
.321
.321
sa
l
Internal
Thread Size
.146
.190
.213
.251
.251
.332
.332
Internal
Thread Size
M2.5x0.45
M3x0.5
M3.5x0.6
M4x0.7
M5x0.8
M6x1
12
.159
.206
.234
.277
.277
.363
.363
Minimum
Boss
Diameter
.344
.438
.500
.594
.594
.750
.750
Part Number
Diameter (mm)
A
B
0.13
0.10
6075L-2.5BR056
6075L-3BR064
6075L-3.5BR064
6075L-4BR079
6075L-5BR111
6075L-6BR127
4.37
5.56
5.56
6.35
8.33
9.53
3.71
4.83
4.83
5.41
7.19
8.43
Length (mm)
L
0.10
5.6
6.4
6.4
7.9
11.1
12.7
Diameter (mm)
C
D
0.03
0.03
3.58
4.70
4.70
5.28
7.06
8.15
4.04
5.23
5.23
5.94
8.00
9.22
Minimum
Boss
Diameter (mm)
8.74
11.13
11.13
12.70
16.66
19.06
C E R T I F I E D
ISO9001QS9000
Ultrasert II Screw-Lock Test Data

ABS
No. 4
No. 6
No. 8
No. 10
1/4"
Length
(In.)
.219
.250
.312
.375
.500
NYLON 6/6
30% G.F.
PREVAILING
**TORQUE**
Rotation Tensile Rotation Tensile Rotation Tensile Rotation Tensile

lbin.
lbs
lbin.
lbs
lbin.
lbs
lbin.
lbs
17
25
45
68
116
258
370
469
726
1157
ABS
Metric
STRUCTURAL
FOAM
23*
45
88*
125
231
417
661
910
1388
2073
24
31
50
72
131
393
487
512
801
1171
21
34
66
133
220
Maximum
211 112 ozin.

509 192 ozin.
883
17 lbin.
1310
20 lbin.
1884
32 lbin.
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Inch
POLYCARBONATE
Length
(mm)
M2.5
5.6
M3 & M3.5
6.4
M4
7.9
M5
11.1
M6
12.7
POLYCARBONATE
STRUCTURAL
FOAM
NYLON 6/6
30% G.F.
1148
1646
2086
3599
5147
2.60*
5.08
9.94*
15.82
26.10
1855
2940
4048
6761
9221
2.75
3.54
5.65
8.08
14.80
1748
2164
2279
3903
5208
2.37
3.84
7.46
19.54
24.86
1468
2264
3928
7037
8380
6.4 ozin.
18 ozin.
1 lbin.
1.5 lbin.
4.5 lbin.
PREVAILING
**TORQUE**
Rotation Tensile Rotation Tensile Rotation Tensile Rotation Tensile

Nm
N
Nm
N
Nm
N
Nm
N
1.92
2.82
5.08
8.81
13.11
Minimum
Maximum
Minimum
.79 Nm
1.36 Nm
1.92 Nm
2.26 Nm
3.62 Nm
.05 Nm
.12 Nm
.11 Nm
.17 Nm
.51 Nm
**Internal thread stripped

**Prevailing torque values are based on the recommended use of cadmium plated screws.
Any other types of screws may affect locking torque values and cycles.
Ultraserts
sa
l
NOTE

C E R T I F I E D
ISO9001QS9000

13
Symmetrical design for low cost,

high volume production
No orientation required
Ultrasert III
Ultrasert III
Ultrasert III is a symmetrical insert designed for high volume

production. The inserts can be loaded into an automatic feeding system without the need for special orientation. The inserts can be installed ultrasonically, with heat or can also be
molded in place. The symmetrical design eliminates the time

required for orientation which produces higher production
and lower overall cost.
MIN. BOSS DIA.

B
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Insert
Specifications
0-80, 2-56; M2x0.4,

M2.2x0.45 & M2.5x0.45
Ultrasert III have two
opposing knurls
MIN. DEPTH =
INSERT LENGTH
PLUS .030 INCH
(0.77 mm)
2-56
4-40
6-32
8-32
10-24
10-32
1/4-20
1/4-28
Part Number
Diameters
A
C
.004
.004
Length
B
.004
Hole Size
D Diam.
+ .003 .000
Minimum
Boss
Diameter
6635-02BR157
6635-04BR226
6635-06BR281
6635-2BR321
6635-3BR375
6641-3BR375
6635-4BR500
6641-4BR500
.135
.179
.220
.250
.281
.281
.342
.342
.157
.226
.281
.321
.375
.375
.500
.500
.128
.159
.190
.223
.254
.254
.317
.317
.286
.372
.440
.498
.558
.558
.684
.684
sa
l
Internal
Thread Size
.123
.154
.185
.218
.249
.249
.312
.312
Internal
Thread Size
M2x0.4
M2.2x0.45
M2.5x0.45
M3x0.5
M3.5x0.6
M4x0.7
M5x0.8
M6x1
14
Part Number
Diameters
A
C
0.10
0.10
Length
B
0.10
Hole Size
D Diam.
+ 0.08 0.00
Minimum
Boss
Diameter
6675-2BR040
6675-2.2BR040
6675-2.5BR057
6675-3BR057
6675-3.5BR071
6675-4BR081
6675-5BR095
6675-6BR127
3.43
3.43
4.54
4.54
5.59
6.35
7.13
8.69
3.99
3.99
5.74
5.74
7.13
8.15
9.52
12.70
3.25
3.25
4.04
4.04
4.83
5.67
6.45
8.05
7.26
7.26
9.44
9.44
11.18
12.64
14.18
17.38
3.12
3.12
3.91
3.91
4.70
5.54
6.32
7.92
C E R T I F I E D
ISO9001QS9000
Ultrasert III Test Data

ABS
NYLON 6/6 30% G.F.
Tensile
lbs
Rotation
lbin.
Tensile
lbs
Rotation
lbin.
Tensile
lbs
81
269
288
381
494
869
7
24
44
75
120
239
163
297
548
804
1006
1666
7
24
44
86
93
230
176
321
518
607
719
1240
8
24
44
83
146
248
166
327
606
647
654
1362
STRUCTURAL FOAM
NYLON 6/6 30% G.F.
Thread Size
Rotation
Nm
Tensile
N
Rotation
Nm
Tensile
N
Rotation
Nm
Tensile
N
Rotation
Nm
Tensile
N
M2 & M2.2
M2.5 & M3
M3.5
M4
M5
M6
.79
2.71
3.95
4.86
6.55
16.17
360
1196
1281
1695
2197
3866
.79
2.71
4.97
8.47
13.56
27.00
725
1321
2438
3576
4475
7411
.79
2.71
4.97
9.72
10.51
25.99
783
1428
2304
2700
3198
5515
.90
2.71
4.97
9.38
16.50
28.02
738
1455
2696
2878
2909
6058
7
24
35
43
58
143
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No. 2
No. 4
No. 6
No. 8
No. 10
1/4"
Tensile
lbs
STRUCTURAL FOAM
Rotation
lbin.
Thread Size
Rotation
lbin.
POLYCARBONATE
ABS
Screw failed
POLYCARBONATE
Ultraserts
NOTE
sa
l



C E R T I F I E D
ISO9001QS9000
15
Ultrasert IV
Provides high tensile and rotational strength

Two lengths to choose from allowing design flexibility
Lead-in pilot positions insert for installation
Parallel sides for installation into straight holes

Diameter
A
.004
.143
.143
.186
.186
.217
.217
.249
.249
.279
.279
.279
.279
.340
.340
.340
.340
.406
.406
.406
.406
.498
.498
.498
.498
B
.003
.123
.123
.154
.154
.185
.185
.218
.218
.249
.249
.249
.249
.312
.312
.312
.312
.374
.374
.374
.374
.465
.465
.465
.465
Length
L
.004
.115
.157
.135
.226
.150
.281
.185
.321
.225
.375
.225
.375
.300
.500
.300
.500
.335
.500
.335
.500
.375
.500
.375
.500
Standard Ultrasert IV
16
Part Number
UMB00204-029
UBM00204
UMB22045-029
UBM22045
UMB25045-034
UBM25045
UMB00305-034
UBM00305
UMB03506-038
UBM03506
UMB00407-047
UBM00407
UMB00508-057
UBM00508
UMB00061-076
UBM00061
UMB08125-085
UBM08125
UMB01015-095
UBM01015
sa
l
Thread Size
M2x0.4
M2x0.4
M2.2x0.45
M2.2x0.45
M2.5x0.45
M2.5x0.45
M3x0.5
M3x0.5
M3.5x0.6
M3.5x0.6
M4x0.7
M4x0.7
M5x0.8
M5x0.8
M6x1.0
M6x1
M8x1.25
M8x1.25
M10x1.5
M10x1.5
Hole Size
D
+ .003 .000
.127
.127
.158
.158
.189
.189
.222
.222
.253
.253
.253
.253
.316
.316
.316
.316
.378
.378
.378
.378
.469
.469
.469
.469
Minimum
Boss
Diameter
.286
.286
.372
.372
.434
.434
.498
.498
.558
.558
es Fo
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Standard Ultrasert IV
Internal
Thread Size
Part Number
2-56
UB000256-115
2-56
UB000256
4-40
UB000440-135
4-40
UB000440
6-32
UB000632-150
6-32
UB000440
8-32
UB000832-185
8-32
UB000832
10-24
UB001024-225
10-24
UB001024
10-32
UB001032-225
10-32
UB001032
1/4-20
UB001420-300
1/4-20
UB001420
1/4-28
UB001428-300
1/4-28
UB001428
5/16-18
UB051618-335
5/16-18
UB051618
5/16-24
UB051624-335
5/16-24
UB051624
3/8-16
UB003816-375
3/8-16
UB003816
3/8-24
UB003824-375
3/8-24
UB003824
Diameter
A
0.10
3.64
3.64
3.64
3.64
4.72
4.72
4.72
4.72
5.51
5.51
6.32
6.32
7.09
7.09
8.64
8.64
10.31
10.31
12.65
12.65
B
0.08
3.12
3.12
3.12
3.12
3.91
3.91
3.91
3.91
4.70
4.70
5.54
5.54
6.32
6.32
7.92
7.92
9.50
9.50
11.81
11.81
.558
.558
.680
.680
.680
.680
.812
.812
.812
.812
.956
.956
.956
.956
Length
L
0.10
2.92
3.99
2.92
3.99
3.43
5.74
3.43
5.74
3.81
7.14
4.70
8.15
5.72
9.53
7.62
12.70
8.51
12.70
9.53
12.70
Hole Size
D
+ 0.08 0.00
3.23
3.23
3.23
3.23
4.02
4.02
4.02
4.02
4.81
4.81
5.65
5.65
6.43
6.43
8.03
8.03
9.61
9.61
11.92
11.92
Minimum
Boss
Diameter
7.26
7.26
7.26
7.26
9.45
9.45
9.45
9.45
11.18
11.18
12.45
12.45
14.17
14.17
17.37
17.37
20.62
20.62
24.28
24.28
C E R T I F I E D
ISO9001QS9000
Ultrasert IV & Test Data

Ultrasert IV
L
MIN. BOSS DIA.

D
MIN. DEPTH =
INSERT LENGTH
PLUS .030 INCH
(0.77 mm)
es Fo
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Ultrasert IV inserts are designed to be installed into straight holes. A lead-in pilot at
the front end of the insert accurately positions the insert prior to installation. It is designed with opposing diagonal knurls that
provide excellent torque resistance and undercuts for tensile strength. Ultrasert IV inserts are designed for ultrasonic or heat installation into thermoplastics or structural
foam materials.
Ultrasert IV Test Data
Note: Test data should be considered as average values for the general families of plastics indicated. Critical application requirements may necessitate further specific testing. The plastic material failed in all cases except where noted.
ABS
Thread
Size
No. 2
No. 4
No. 6
No. 8
No. 10
1/4"
5/16"
3/8"
Length
Rotation
lbin.
.115
.157
.135
.226
.150
.281
.185
.321
.225
.375
.300
.500
.335
.500
.375
.500
**
6
**
15.8
**
27
**
44
**
76
**
118
**
168
**
336
POLYCARBONATE
Tensile
lbs
**
110
**
228
**
298
**
440
**
622
**
887
**
980
**
1334
ABS
Length
(mm)
Rotation
N-m
M2 & M2.2
2.92
3.99
3.43
5.74
3.81
7.14
4.70
8.15
5.72
9.53
7.62
12.70
8.51
12.70
9.53
12.70
**
.68
**
1.79
**
3.05
**
4.97
**
8.59
**
13.33
**
18.98
**
37.96
M2.5 & M3
M3.5
M4
M5
M6
M8
M10
sa
l
Thread
Size
Rotation
lbin.
Tensile
lbs
Rotation
lbin.
**
11*
**
23*
**
45*
**
85*
**
120*
**
210
**
313*
**
534
**
200
**
338
**
598
**
831
**
1026
**
1717
**
1840
**
2306
**
10
**
23*
**
45*
**
68
**
99
**
171
**
265
**
411
POLYCARBONATE
Tensile
N
**
489
**
1014
**
1326
**
1957
**
2767
**
3946
**
4359
**
5934
STRUCTURAL FOAM
Rotation
N-m
**
1.24
**
2.60*
**
5.08*
**
9.60*
**
13.56
**
23.73
**
35.36
**
60.33
Tensile
N
**
890
**
1503
**
2660
**
3696
**
4564
**
7638
**
8185
**
10258
Tensile
lbs
**
177
**
329
**
388
**
567
**
748
**
871
**
1231
**
1315
STRUCTURAL FOAM
NYLON 6/6 30% G.F.

Rotation
lbin.
**
13*
**
23*
**
45*
**
90*
**
139
**
213
**
316
**
663
Tensile
lbs
**
159
**
350
**
488
**
583
**
862
**
1100
**
1618
**
2938
NYLON 6/6 30% G.F.
Rotation
N-m
Tensile
N
Rotation
N-m.
**
1.13
**
2.60*
**
5.08*
**
7.68
**
11.19
**
19.32
**
29.94
**
46.44
**
787
**
1463
**
1726
**
2522
**
3327
**
3874
**
5476
**
5849
**
1.47*
**
2.60*
**
5.08*
**
10.17*
**
15.70
**
24.07
**
35.70
**
74.91
Tensile
N
**
707
**
1557
**
2171
**
2593
**
3834
**
4893
**
7197
**
13069
* Screw failed
** Please contact Applications Engineering/for test data.
C E R T I F I E D
ISO9001QS9000
17
Ultrasert IV Flanged
Provides high tensile and rotational strength

Flange provides a large bearing surface
Ideal for an electrical contact; fastening terminal connectors

Diameter
A
.005
.188
.188
.219
.219
.250
.250
.281
.281
.313
.313
.313
.313
.375
.375
.375
.375
.438
.438
.438
.438
.550
.550
.550
.550
B
.003
.123
.123
.154
.154
.185
.185
.218
.218
.249
.249
.249
.249
.312
.312
.312
.312
.374
.374
.374
.374
.465
.465
.465
.465
Length
L
.004
.133
.175
.156
.247
.177
.308
.218
.354
.265
.415
.265
.415
.350
.550
.350
.550
.385
.550
.385
.550
.440
.565
.440
.565
Flange
Thickness
C
.003
.018
.018
.021
.021
.027
.027
.033
.033
.040
.040
.040
.040
.050
.050
.050
.050
.050
.050
.050
.050
.065
.065
.065
.065
Flanged Ultrasert IV
Internal
Thread Size
Part Number
Minimum
Boss
Diameter
.286
.286
.372
.372
.434
.434
.498
.498
Diameter
.558
.558
.558
.558
.680
.680
.680
.680
.812
.812
.812
.812
.956
.956
.956
.956
A
0.13
B
0.08
Length
L
0.10
Flange
Thickness
C
0.08
Hole Size
D
+ 0.08 0.00
Minimum
Boss
Diameter
UFBM00204-034
UFBM00204
4.78
4.78
3.12
3.12
3.38
4.45
0.46
0.46
3.23
3.23
7.26
7.26
M2.2x0.45
M2.2x0.45
UFBM22045-034
UFBM22045
4.78
4.78
3.12
3.12
3.38
4.45
0.46
0.46
3.23
3.23
7.26
7.26
M2.5x0.45
M2.5x0.45
UFBM25045-039
UFBM25045
5.56
5.56
3.91
3.91
3.96
6.27
0.53
0.53
4.02
4.02
9.45
9.45
UFBM00305-039
UFBM00305
5.56
5.56
3.91
3.91
3.96
6.27
0.53
0.53
4.02
4.02
9.45
9.45
M3.5x0.6
M3.5x0.6
UFBM03506-045
UFBM03506
6.35
6.35
4.70
4.70
4.50
7.82
0.69
0.69
4.81
4.81
11.18
11.18
M4x0.7
M4x0.7
UFBM00407-055
UFBM00407
7.14
7.14
5.54
5.54
5.54
8.99
0.84
0.84
5.65
5.65
12.45
12.45
M5x0.8
M5x0.8
UFBM00508-067
UFBM00508
7.95
7.95
6.32
6.32
6.73
10.54
1.02
1.02
6.43
6.43
14.17
14.17
M6x1.0
M6x1
UFBM00061-089
UFBM00061
9.53
9.53
7.92
7.92
8.89
13.97
1.27
1.27
8.03
8.03
17.37
17.37
M8x1.25
M8x1.25
UFBM08125-098
UFBM08125
11.13
11.13
9.50
9.50
9.78
13.97
1.27
1.27
9.61
9.61
20.62
20.62
M10x1.5
M10x1.5
UFBM01015-111
UFBM01015
13.96
13.96
11.81
11.81
11.18
14.35
1.65
1.65
11.92
11.92
24.28
24.28
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M2x0.4
M2x0.4
M3x0.5
M3x0.5
18
Hole Size
D
+ .003 .000
.127
.127
.158
.158
.189
.189
.222
.222
.253
.253
.253
.253
.316
.316
.316
.316
.378
.378
.378
.378
.469
.469
.469
.469
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Flanged Ultrasert IV
Internal
Thread Size
Part Number
2-56
UFB000256-133
2-56
UFB000256
4-40
UFB000440-156
4-40
UFB000440
6-32
UFB000632-177
6-32
UFB000632
8-32
UFB000832-218
8-32
UFB000832
10-24
UFB001024-265
10-24
UFB001024
10-32
UFB001032-265
10-32
UFB001032
1/4-20
UFB001420-350
1/4-20
UFB001420
1/4-28
UFB00148-350
1/4-28
UFB001428
5/16-18
UFB51618-385
5/16-18
UFB051618
5/16-24
UFB051624-385
5/16-24
UFB051624
3/8-16
UFB003816-440
3/8-16
UFB003816
3/8-24
UFB003824-440
3/8-24
UFB003824
C E R T I F I E D
ISO9001QS9000
Ultrasert IV Flanged & Test Data

L
MIN. BOSS DIA.
The Flanged Ultrasert IV insert has the same characteristics as the standard Ultrasert IV with the added benefit of
a flange. The flange provides a large bearing surface which
is advantageous in weaker plastics. For high strength assemblies they can be used in a reverse screw entry.
MIN. DEPTH =
INSERT LENGTH
PLUS .030 INCH
(0.77 mm)
Ultrasert IV Flanged
TEST DATA FROM FLANGE SIDE

ABS
Length (inch)
No. 2
No. 4
No. 6
No. 8
No. 10
1/4"
5/16"
3/8"
.175
.247
.308
.354
.415
.550
.550
.565
POLYCARBONATE
Rotation
lb-in.
Tensile
lbs
6
15.8
27
44
76
118
168
336
110
228
298
440
622
887
980
1334
ABS
Thread
Size
M2 & M2.2
M2.5 & M3
M3.5
M4
M5
M6
M8
M10
STRUCTURAL FOAM
Rotation
lb-in.
Tensile
lbs
Rotation
lb-in.
Tensile
lbs
11
23*
45*
85*
120
210
313
534
200
338
598
831
1026
1717
1840
2306
10
23*
45*
68
99
171
265
411
177
329
388
567
748
871
1231
1315
NYLON 6/6 30% G.F.

Rotation
lb-in
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Thread
Size
Length (mm)
4.45
6.27
7.82
8.99
10.54
13.97
13.97
14.35
Rotation
N-m
.68
1.79
3.05
4.97
8.59
13.33
18.98
37.96
POLYCARBONATE
Tensile
N
489
1014
1326
1957
2767
3946
4359
5934
STRUCTURAL FOAM
13
23*
45*
90*
139
213
316
663
Tensile
lbs
159
350
488
583
662
1100
1618
2938
NYLON 6/6 30% G.F.
Rotation
N-m
Tensile
N
Rotation
N-m
Tensile
N
Rotation
N-m
1.24
2.60*
5.08*
9.60*
13.56
23.73
35.36
60.33
890
1503
2660
3696
4564
7638
8185
10258
1.13
2.60*
5.08*
7.68
11.19
19.32
29.94
46.44
787
1463
1726
2522
3327
3874
5476
5849
1.47*
2.60*
5.08*
10.17*
15.70
24.07
35.70
74.91
Tensile
N
707
1557
2171
2593
3834
4893
7197
13069
TEST DATA FOR LOADS APPLIED FROM OPPOSITE END

ABS
Length (inch)
No. 2
No. 4
No. 6
No. 8
No. 10
1/4"
5/16"
3/8"
.175
.247
.308
.354
.415
.550
.550
.565
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Thread
Size
Rotation
lb-in.
POLYCARBONATE
Tensile
lbs
6
15.8
27
44
76
118
168
336
292
573
846
1161
1251
1409
1759
2714
ABS
Thread
Size
M2 & M2.2
M2.5 & M3
M3.5
M4
M5
M6
M8
M10
Length
4.45
6.27
7.82
8.99
10.54
13.97
13.97
14.35
Rotation
N-m
.68
1.79
3.05
4.97
8.59
13.33
18.98
37.96
Rotation
lb-in.
Tensile
lbs
Rotation
lb-in.
Tensile
lbs
11
23*
45*
85*
120
210
313
534
359
827
1294
1952
2159
2369
2720
4904
10
23*
46*
68
99
171
265
411
367
711
966
1310
1557
1800
2003
3083
POLYCARBONATE
Tensile
N
1299
2549
3763
5164
5565
6268
7824
12072
STRUCTURAL FOAM
STRUCTURAL FOAM
Rotation
N-m
Tensile
N
Rotation
N-m
1.24
2.60*
5.08*
9.60*
13.56
23.73
35.36
60.33
1597
3679
5756
8683
9604
10538
12099
21814
1.13
2.60*
5.08*
7.68
11.19
19.32
29.94
46.44
Tensile
N
1632
3163
4297
5827
6976
8006
8910
13714
NYLON 6/6 30% G.F.

Rotation
lb-in
13
23*
46*
90*
139
213
316
663
Tensile
lbs
382
840
1329
1939
2113
2881
2925
5678
NYLON 6/6 30% G.F.

Rotation
N-m
1.47*
2.60*
5.08*
10.17*
15.70
24.07
35.70
74.91
Tensile
N
1699
3737
5912
8625
9399
12815
13011
25257
* Screw failed.
NOTE: Test data is for long lengths only. Please contact Applications Engineering for short length test data.
C E R T I F I E D
ISO9001QS9000
19
Provides a pressure tight assembly

Easy installation and self alignment
Exceeds rotational and tensile requirements
Ultraseal Inserts
Ultraseal Pipe Thread Inserts for Plastics
The Ultraseal Pipe Thread Insert is an innovative design
that provides a pressure tight seal over a broad range of
operating temperatures.
Ultraseal Pipe Thread Inserts are designed to be installed
after molding using either ultrasonics or heat. They provide the high performance strength values of molded-in
inserts while still retaining all the economical advantages
of insert installation after molding.
The O-Ring is the key feature that provides the pressure tight seal. It withstands 600F installation temperature and will function at operating temperatures up to
400F. When installed into the recommended hole size
it will offer a high performance seal between the plastic
and the insert.
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ORING
INSERT SPECIFICATIONS
Thread Size
1/8-27
1/4-18
3/8-18
HOLE RECOMMENDATION
Part Number*
Length
A
Diameter
B
Diameter
C
Diameter
D
Length
E min
6092-2**BM400
6092-4**BM475
6092-6**BM500
.400
.475
.500
.614
.736
.883
.607
.727
.870
.567
.685
.817
.430
.505
.530
* Note: To order, complete the part number by adding the code letters which correspond to the type of internal thread
required from the chart below. Example: For 1/8-27 NPT brass insert, the part number will be 6092-2PTBM400.
Thread
ANPT
20
Assembly Strength Data
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THREAD TYPE
Code
AT
NPT
PT
NPTF
TF
NPSI
SI
NPSF
SF
NPSC
SC
Dodge Ultraseal Pipe Thread Inserts provide high tensile and torque loads
in addition to their sealing features. The combination of diagonal knurls
and undercuts provides a unique anchoring arrangement. Average test
values are for reference purposes.
Size
Tensile
1/8-27
526 lbs
1/4-18
1000 lbs
3/8-18
1586 lbs
Material: 30% Glass filled nylon 6/6
Rotational
Torque
Recommended
Pressure
335 lb.-in
575 lb.-in
950 lb.-in
Up to 250 PSI
Up to 250 PSI
Up to 250 PSI
C E R T I F I E D
ISO9001QS9000
Two-piece design allows full thread engagement in

minimum space
Controlled minor diameter assures accurate alignment
Can be installed with heat as well as molded in
Ultra-Mold Inserts
Ultra-Mold
The Ultra-Mold insert was designed for applications where a
molded-in insert is more economical than post molding. The
unique two-piece design means that there are full threads
through the entire length of the insert. No added material is
required for imperfect threads and drill point. This saves space
and weight. The manufacturing process eliminates machining
chips and oil residue that can contaminate plastic molded parts.
The Ultra-Mold insert has a controlled minor diameter which

reduces movement during molding and assures accurate
alignment of the insert in the part. Ultra-Mold is designed
with a unique counterbore that accurately positions the insert over the molding pin and allows easy bolt entry at assembly. The insert design ensures optimum strength performance in a minimum of space.
Flanged
Thickness
C
.005
INCH STANDARD SPECIFICATIONS

Internal
Thread Size
Part Number
Diameter (inches)
A
B
.008
.010
Length
L
.005
8-32
10-24
10-32
1/4-20
1/4-28
5/16-18
5/16-24
3/8-16
3/8-24
.281
.312
.312
.375
.375
.438
.438
.593
.593
.297
.347
.347
.442
.442
.556
.556
.645
.645
.020
.025
.025
.030
.030
.035
.035
.040
.040
Flanged
Thickness
C
0.08
.250
.280
.280
.340
.340
.405
.405
.514
.514
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6176-2BA297
6176-3BA347
6177-3BA347
6176-4BA442
6177-4BA442
6176-5BA556
6177-5BA556
6176-6BA645
6177-6BA645
METRIC STANDARD SPECIFICATIONS

Internal
Thread Size
Part Number
Diameter (mm)
A
B
0.13
0.08
Length
L
0.10
M4x0.7
M5x0.8
M6x1.0
M8x1.25
M10x1.5
7.14
7.93
9.53
11.13
15.07
7.55
8.82
11.23
14.13
16.39
6175-4BA075
6175-5BA088
6175-6BA1123
6175-8BA1413
6175-10BA1639
6.35
7.12
8.64
10.29
13.06
A DIA.
0.50
0.64
0.77
0.89
1.02
Ultra-Mold Test Data
ABS
POLYCARBONATE
NYLON 6/6
Thread
Size
Rotation
lb-in.
Tensile
lbs
Rotation
lb-in.
Tensile
lbs
Rotation
lb-in.
Tensile
lbs
6176-2BA297
6176-3BA347
6177-3BA347
6176-4BA442
6177-4BA442
6176-5BA556
6177-5BA556
6176-6BA645
6177-6BA645
8-32
10-24
10-32
1/4-20
1/4-28
5/16-18
5/16-24
3/8-16
3/8-24
54
85
85
170
170
302
302
538
538
456
632
632
993
993
1428
1428
2138
2138
69
107
107
249
249
457
457
567
567
593
744
744
1393
1393
2097
2097
2710
2710
85
128
128
230
230
389
389
812
812
813
1137
1137
1454
1454
2957
2957
4107
4107
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Part
Number
ABS
Part
Number
6175-4BA075
6175-5BA088
6175-6BA1123
6175-8BS1413
6175-10BA1639
C E R T I F I E D
ISO9001QS9000
Thread
Size
M4x0.7
M5x0.8
M6x1
M8x1.25
M10x1.5
POLYCARBONATE
NYLON 6/6
Ultra-Mold
Conventional
The unique two-piece design allows full and complete threads throughout the
entire length of the insert.
No extra material is needed
Rotation
N-m
Tensile
N
Rotation
N-m
Tensile
N
Rotation
N-m
Tensile
N
for imperfect threads and
6.10
9.60
19.21
34.12
60.78
2028
2811
4417
6352
9510
7.80
12.15
28.13
51.63
64.06
2638
3311
6196
9327
12054
9.60
14.46
25.99
43.95
91.74
3616
5057
6467
13153
18268
drill point. This saves space
and weight; it also reduces

costs.
21
Available in flanged and symmetrical styles

Lead in pilot positions insert for installation
Designed for installation into straight holes
Can be molded in or installed with heat
Miniature Inserts
Miniature Inserts
Dodge Miniature Inserts are designed to meet the requirements of
todays electronic, telecommunications and computer markets. The
trend towards more miniaturized and compact consumer products
has necessitated the use of smaller screws which must be reusable
without the possibility of thread damage. Dodge Miniature Inserts
provide the strong, reusable threads designers need. They are available in two styles. The symmetrical style is designed for high production. They can be loaded and fed through automatic installation equip-
ment without the need for special orientation. This eliminates the time
required for orientation, which lowers overall cost by increasing productivity. The flanged style insert provides a larger bearing surface for
electrical contact and greater strength in weaker plastics. Both inserts
are designed with opposing diagonal knurls and undercuts for exceptional rotational and tensile strength. They can be installed with heat
or molded in.
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MIN. BOSS DIA.

D
MIN. DEPTH =
INSERT LENGTH
PLUS .030 INCH
(0.77 mm)
SYMMETRICAL STYLE INSERT
Diameters
Internal
Thread Size
Part Number
M1.6x0.35
6200-1.6BR030
A
0.10
B
0.08
Length
L
0.13
2.50
2.06
3.00
Diameter
D
+ 0.05 0.00
Minimum
Boss
Diameter
2.14
4.63
MIN. BOSS DIA.

D
MIN. DEPTH =
INSERT LENGTH
PLUS .030 INCH
(0.77 mm)
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FLANGED STYLE INSERT

INSERT SPECIFICATIONS (mm)
Flanged Miniature
22
Diameter
Thread Size
Part Number
A
0.13
B
0.08
Length
L
0.13
M1.6x0.35
6201-1.6BR033
3.18
2.06
3.31
Flange
Thickness
C
0.10
Diameter
D
+ 0.05 0.00
0.41
2.14
Minimum
Boss
Diameter
4.63
C E R T I F I E D
ISO9001QS9000
strength requirements of the specific application. These
inserts can be installed with heat or ultrasonics, or they
can be pressed in place. Our Dodge Applications Engineers are available and ready to assist you in the design
and development of the optimum bushing for your application. We can also provide sample parts and test data.
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Dodge offers compression limiters for applications

where the tightening load of the bolt or screw will compress, crack or otherwise damage the plastic component.
Compression limiters are non-threaded bushings made
of various materials. They are designed with various knurl
configurations and undercuts in order to meet the
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Eliminate cracking of plastic parts due to bolt load

Can be pressed in or installed with heat or ultrasonics
Custom designed for each application
C E R T I F I E D
ISO9001QS9000
23
Standard Expansion
Versatile can be used in any type of plastic

Simple press-in installation
Standard Expansion Inserts

Standard Expansion Inserts are easy to install, two-piece,
brass, expandable inserts for use in blind holes in thermoset or thermoplastic materials. When the captivated
spreader plate is depressed, the knurled portion of the insert expands, permanently anchoring the insert in the hole.
If desired, the insert can be installed to protrude above the

surface of the part to act as an assembly-locating device.
L
MIN. BOSS DIA.
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Standard Expansion
Thread Size
Part Number
4-40
5-40
6-32
6-32
8-32
8-32
10-24
10-24
10-32
10-32
10-32
1/4-20
5/16-18
70015-04-250
70015-05-313
70015-06-313
70015-06-375
70015-2-313
70015-2-375
70015-3-375
70015-3-438
70011-3-313
70011-3-375
70011-3-438
70015-4-500
70015-5-625
Body
Diameter
A
.003
Installed
Length
L
.004
Minimum
Threaded
Length
B
Diameter*
C
.001
Depth
D
Ref.
.156
.188
.188
.188
.219
.219
.250
.250
.250
.250
.250
.313
.438
.250
.313
.313
.375
.313
.375
.375
.438
.313
.375
.438
.500
.625
.178
.240
.240
.303
.240
.303
.303
.365
.240
.303
.365
.428
.537
.158
.190
.190
.190
.221
.221
.252
.252
.252
.252
.252
.315
.440
.250
.313
.313
.375
.313
.375
.375
.438
.313
.375
.438
.500
.625
Minimum
Boss
Diameter
.312
.376
.376
.376
.438
.438
.500
.500
.500
.500
.500
.626
.876
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*Diameter C is for Thermoset Plastics. For Thermoplastic materials, refer to page 25.
Standard Expansion
Thread Size
Part Number
M3x0.5
M3.5x0.6
M4x0.7
M4x0.7
M5x0.8
M5x0.8
M6x1
70017-3-064
70017-3.5-080
70017-4-080
70017-4-095
70017-5-080
70017-5-095
70017-6-127
Body
Diameter
A (mm)
0.08
Installed
Length
L (mm)
0.10
Minimum
Threaded
Length
B (mm)
Diameter*
C (mm)
0.03
Depth
D (mm)
Ref.
3.96
4.78
5.56
5.56
6.35
6.35
7.95
6.40
8.00
8.00
9.50
8.00
9.50
12.70
4.52
6.10
6.10
7.70
6.10
7.70
10.87
4.01
4.83
5.61
5.61
6.40
6.40
8.00
6.40
8.00
8.00
9.50
8.00
9.50
12.70
Minimum
Boss
Diameter
7.92
9.56
11.12
11.12
12.70
12.70
15.90
*Diameter C is for Thermoset Plastics. For Thermoplastic materials, refer to page 25.
24
C E R T I F I E D
ISO9001QS9000
Standard Expansion Test Data

EXPANSION INSERT TEST DATA*
EXPANSION INSERTS
Inch
Size
POLYCARBONATE
PHENOLIC
Metric
Size
Insert
Length
Rotation
lbin.
Tensile
lbs
Rotation
lbin.
Tensile
lbs
Rotation
lb-in.
Tensile
lbs
M2.5
M3 & M3.5
M4
M5
M6
.250
.313
.375
.375
.438
.500
.625
13
21
22
44
55
88
1105
105
181
173
257
342
436
606
24*
31
34
54
81
101
133
215
239
231
317
354
465
699
24*
35*
41*
73*
93
97
110
171
196
199
318
364
497
600
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No. 4
No. 5
No. 6
No. 8
No. 10
1/4
5/16
ABS
*To achieve maximum strength,spreader plate must be pushed to the bottom of the hole as shown in Fig. 2.
Fig. 1
Fig. 2
Expansion Principle
Standard
Flange
Clinch Inserts
These inserts are two piece units

consisting of threaded insert and a
captivated spreader plate. When this
spreader plate is depressed, the knurled
portion of the insert expands and
anchors the insert in the hole.
Expansion inserts must be expanded by
depressing the spreader plate prior to
insertion of the screw. The screw will
not expand the insert and lock it in
place.
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The Expansion Inserting Tooling shown

on page 27 provides an economical and
efficient means of installing the inserts.
The Dodge hand tool works best in

thermoset materials. Since the receiving
hole diameter is .002 larger than the
insert diameter, the insert drops freely
into the hole and is ready to be expanded using this tool.
C E R T I F I E D
ISO9001QS9000
Expansion inserts are to be used only in blind holes.
For thermoplastic materials, the

receiving hole diameter is .003
smaller than the insert diameter.
Because there is interference, the insert
must be pressed to the bottom of the
hole prior to expanding it. The shoulder
on the tool installs the insert. Once it
has bottomed, tension on an internal
spring is overcome and the punch
depresses the spreader plate permanently anchoring the insert in the hole.
DO NOT push the spreader plate
too deep. This will reduce the
holding strength of the insert
significantly.
NOTE
The test data should be considered as average values

for the general families of
plastics indicated. Critical
application requirements
may necessitate further
specific testing.
The plastic material failed
in all cases except where
noted.
25
Clinch and Flange

Expansion Inserts
Same superior design characteristics

as Standard Expansion Inserts
Simple installations
L
MIN. BOSS DIA.
B
A
.030 INCH ALL
SIZES
(.077mm)
4-40
4-40
6-32
6-32
8-32
8-32
Body
Diameter
A
.003
70515-04A250
70515-04B226
70515-06A313
70515-06B289
70515-2A375
70515-2B351
**Metric Clinch**
Expansion
Thread
Part
Size
Number
M3x0.5
M3.5x0.6
M4x0.7
Installed Minimum
Clinch
Flange Clinch
Length Threaded
Height
Diameter O.D. Diameter* Depth
L
Length
C
D
E
F
G
.004
B
+.012 .000 .003
.002 .001
Ref.
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Thread
Size
Inch Clinch
Expansion
Part
Number
.156
.156
.188
.188
.219
.219
.250
.226
.313
.289
.375
.351
.178
.154
.240
.216
.303
.279
.040
.064
.040
.064
.040
.064
.219
.219
.250
.250
.281
.281
.138
.138
.164
.164
.190
.190
.158
.158
.190
.190
.221
.221
.250
.226
.313
.289
.375
.351
Body
Installed Minimum
Clinch
Flange Clinch
Diameter Length Threaded
Height
Diameter O.D. Diameter* Depth
A
L
Length
C
D
E
F
G
0.08
0.10
B
+0.30 0.00 0.08
0.05 0.03
Ref.
70517-3A064
70517-3.5A080
70517-4A095
3.96
4.78
5.56
6.40
8.00
9.50
4.52
6.10
7.70
1.00
1.00
1.00
5.56
6.35
7.14
3.51
4.17
4.83
4.01
4.82
5.61
6.40
8.00
9.50
Minimum
Boss
Diameter
.312
.312
.376
.376
.438
.438
Minimum
Boss
Diameter
7.42
9.56
11.12
*Diameter F is for Thermoset Plastics. For Thermoplastic materials, refer to page 25. **Dimensions are in millimeters.
L
MIN. BOSS DIA.
.030 ALL SIZES

(0.77mm)
4-40
6-32
8-32
10-24
10-32
1/4-20
70315-04-219
70315-06-281
70315-2-281
70315-3-313
70311-3-313
70315-4-438
**Metric Flange**
Expansion
Thread
Part
Size
Number
M3x0.5
M3.5x0.6
M4x0.7
M5x0.8
M6x1
Body
Diameter
A
.003
Installed
Length
L
.004
Minimum
Threaded
Length
B
Flange
Diameter
C
.003
Diameter*
D
.001
Depth
E
Ref.
.156
.188
.219
.250
.250
.313
.219
.281
.281
.313
.313
.438
.146
.209
.209
.240
.240
.365
.219
.250
.281
.313
.313
.406
.158
.190
.221
.252
.252
.315
.219
.281
.281
.313
.313
.438
Body
Diameter
A
0.08
Installed
Length
L
0.10
Minimum
Threaded
Length
B
Flange
Diameter
C
0.08
Diameter*
D
0.03
Depth
E
Ref.
3.96
4.78
5.56
6.35
7.95
5.60
7.10
7.10
8.00
11.10
3.71
5.31
5.31
6.10
9.27
5.56
6.35
7.14
7.95
10.31
4.01
4.82
5.61
6.40
8.00
5.60
7.10
7.10
8.00
11.10
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Thread
Size
Inch Flange
Expansion
Part
Number
70317-3-056
70317-3.5-071
70317-4-071
70317-5-080
70317-6-111

Minimum
Boss
Diameter
.312
.376
.438
.500
.500
.626
Minimum
Boss
Diameter
7.92
9.56
11.12
12.70
15.90
*Diameter D is for Thermoset Plastics. For Thermoplastic materials, refer to page 25. **Dimensions are in millimeters.
26
C E R T I F I E D
ISO9001QS9000
Clinch and Flange Test Data

Clinch Insert
Flange Insert
Clinch inserts feature a pilot and a flange and have the same
design characteristics as Standard Expansion Inserts. The
inserts are used extensively in the electrical industry. The
pilot can be clinched over a terminal connector with the
flange providing a large surface for electrical contact. The
installation and clinching operations are simultaneous using
a simple press-in type tool. Like the Flange Insert, much of
the installation force is absorbed by the flange allowing use
in thin-section applications.
The Flange Insert in addition to having all of the design

features of the Standard Insert, has a flange with a large
bearing surface. The flange can be used to make an electrical
contact or to fasten a terminal connector. The flange can also
be used to join mating parts by inserting the body of the
insert through the mating part and into the receiving hole in
the parent material. The insert is excellent for use in thinsection applications since the flange absorbs much of the
installation force.
NOTE
EXPANSION INSERTS
Inch
Size
No. 4
No. 5
No. 6
No. 8
No. 10
1/4
5/16
Metric
Size
The test data should be

considered as average
values for the general
families of plastics indicated. Critical application requirements
may necessitate further
specific testing. The
values shown are for
Standard Expansion Inserts. These values
would also apply to
Flange and Clinch Inserts of comparable
lengths.
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EXPANSION INSERT TEST DATA*
M2.5
M3 & M3.5
M4
M5
M6
ABS
POLYCARBONATE
PHENOLIC
Insert
Length
Rotation
lbin.
Tensile
lbs
Rotation
lbin.
Tensile
lbs
Rotation
lb-in.
Tensile
lbs
.250
.313
.375
.375
.438
.500
.625
13
21
22
44
55
88
1105
105
181
173
257
342
436
606
24*
31
34
54
81
101
133
215
239
231
317
354
465
699
24*
35*
41*
73*
93
97
110
171
196
199
318
364
497
600
*To achieve maximum strength, spreader plate must be pushed to the bottom of the hole as shown in
Fig. 2 on page 25.
Expansion Insert Tooling
Ordering Informination
EXPANSION INSERT TOOLING INCH
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Semi-Automatic Model. May be used to install Dodge Standard Flange

and Wedge Inserts. The tool consists essentially of a punch and a springloaded sleeve. It must be chucked in an arbor press or foot press. It is not
designed to be driven by a hammer. Basic part number is 79005 for inch and
79027 for metric.
Hand Tool. May be used to install Dodge Standard, Flange and Wedge
Inserts. The tool may be used with hammer or chuck in an arbor press or
foot press. Basic part number is 79015 for inch and 79017 for metric.
Inch
Size
SemiAutomatic
Clinch
Tool
Hand Tool*
No. 4
No. 5
No. 6
No. 8
No. 10
1/4"
5/16"
79005-04
79005-05
79005-06
79005-2
79005-3
79005-4
79005-5
79035-04
79035-06
79035-2
79015-04***
79015-05***
79015-06***
79015-2***
79015-3***
79015-4***
79015-5***
*The length of the insert being used must be included in the

hand tool part number.
EXPANSION INSERT TOOLING METRIC
The Clinch Insert Model. Designed to install and crimp Dodge Clinch
Inserts. The tool consists of a punch and a spring-loaded sleeve with a radius
section which crimps the eyelet portion of the insert over the mating
component. It must be chucked in an arbor press or foot press. Basic part
number is 79035 for inch and 79047 for metric.
C E R T I F I E D
ISO9001QS9000
Metric
Size
SemiAutomatic
Clinch
Tool
Hand Tool*
M3
M3.5
M4
M5
M6
79027-3
79027-3.5
79027-4
79027-5
79027-6
79047-3
79047-3.5
79047-4
79017-3***
79017-3.5***
79017-4***
79017-5***
79017-6***
*The length of the insert being used must be included in the

hand tool part number.
27
Install easily into thermoset or

thermoplastic materials
Slots provide rapid cutting action
Self Threading Inserts

MIN. BOSS DIA.
E
F
2-56
4-40
6-32
8-32
10-24
10-32
1/4-20
1/4-28
ST086-56
ST112-40
ST138-32
ST164-32
ST190-24
ST190-32
ST250-20
ST250-28
Metric Self
*Threading Inserts*
Thread
Part
Size
Number
Body
Diameter
A
.006
Length
L
.010
Pilot
Diameter
B
Ref.
C
Thermoset
C
Thermoplastic
Hole
Depth
D
Ref.
.141
.172
.219
.250
.297
.297
.375
.375
.187
.234
.281
.328
.375
.375
.484
.484
.122
.149
.189
.219
.261
.261
.330
.330
.129/.127
.156/.152
.198/.194
.230/.226
.270/.264
.270/.264
.343/.336
.343/.336
.124/.127
.149/.152
.190/.194
.222/.226
.259/.264
.259/.264
.330/.336
.330/.336
.225
.281
.337
.394
.450
.450
.581
.581
Body
Diameter
A
0.15
Length
L
0.25
Pilot
Diameter
B
Ref.
C
Thermoset
C
Thermoplastic
Hole
Depth
D
Ref.
4.75
4.75
5.94
7.14
7.14
8.33
9.53
12.29
3.10
3.10
3.35
4.32
4.32
4.95
5.89
7.67
3.28/3.23
3.28/3.23
3.96/3.86
5.03/4.93
5.03/4.93
5.84/5.74
6.86/6.71
8.71/8.53
3.17/3.24
3.17/3.24
3.78/3.86
4.83/4.93
4.83/4.93
5.63/5.74
6.58/6.71
8.38/8.58
5.72
5.72
7.14
8.56
8.56
10.01
11.43
14.76
M2x0.4
STM2x0.4
3.58
M2.2x0.45 STM2.2x0.45
3.58
M2.5x0.45 STM2.5x0.45
4.37
M3x0.5
STM3x0.5
5.56
M3.5x0.6
STM3.5x0.6
5.56
M4x0.7
STM4x0.7
6.35
M5x0.8
STM5x0.8
7.54
M6x1
STM6x1
9.53
*Dimensions are in millimeters
Hole
Diameter
Counter Bore
Minimum
Diameter Depth
Boss
E
F
Diameter
.001
Ref.
Hole
Diameter
Extension
Inserting
Tool
.141
.172
.219
.250
.295
.295
.375
.375
.032
.042
.050
.050
.056
.056
.063
.063
.280
.344
.437
.500
.594
.594
.750
.750
Counter Bore
Minimum
Diameter Depth
Boss
E
F
Diameter
0.03
Ref.
3.58
3.58
4.37
5.56
5.56
6.35
7.50
9.53
.81
.81
1.07
1.27
1.27
1.27
1.42
1.60
7.2
7.2
8.7
11.1
11.1
12.7
15.1
19.1
Hand
Inserting
Tool
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Standard
Inserting
Tool
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Inch Self
Threading Inserts
Thread
Part
Size
Number
SELF THREADING TOOLING INCH

Inch
Size
2-56
4-40
6-32
8-32
10-24
10-32
1/4-20
1/4-28
28
STANDARD
Inserting Tool
Part No.
5301-02
5301-04
5301-06
5301-2
5301-3
5302-3
5301-4
5302-4
EXTENSION
Inserting Tool
Part No.
5301-02-15
5301-04-15
5301-06-15
5301-2-15
5301-3-15
5302-3-15
5301-4-15
5302-4-15
HAND
Inserting Tool
Part No.
5311-02
5311-04
5311-06
5311-2
5311-3
5312-3
5311-4
5312-4
SELF THREADING TOOLING METRIC

Metric
Size
M2x0.4
M2.2x0.45
M2.5x0.45
M3x0.5
M3.5x0.6
M4x0.7
M5x0.8
M6x1
STANDARD
Inserting Tool
Part No.
5370-2
5370-2.2
5370-2.5
5370-3
5370-3.5
5370-4
5370-5
5370-6
EXTENSION
Inserting Tool
Part No.
5370-2-15
5370-2.2-15
5370-2.5-15
5370-3-15
5370-3.5-15
5370-4-15
5370-5-15
5370-6-15
HAND
Inserting Tool
Part No.
5380-2
5380-2.2
5380-2.5
5380-3
5380-3.5
5380-4
5380-5
5380-6
C E R T I F I E D
ISO9001QS9000
Flange provides larger bearing

surface
Slots provide rapid cutting action
Flanged Self Threading

MIN. BOSS DIA.
E
F
2-56
4-40
6-32
8-32
10-24
10-32
1/4-20
1/4-28
Pilot
Diameter
A
Ref.
Flange
Diameter
B
.005
Flange
Thickness
W
.004
Length
L
.010
.122
.132
.170
.195
.232
.232
.302
.302
.186
.218
.250
.281
.375
.375
.438
.438
.020
.025
.030
.035
.040
.040
.045
.045
.228
.298
.355
.360
.404
.404
.460
.460
Hole
Diameter
C
Thermoset
C
Thermoplastic
Hole
Depth
D
Ref.
.129-.127
.156-.152
.198-.194
.230-.226
.270-.264
.270-.264
.343-.336
.343-.336
.127-.124
.152-.149
.194-.190
.226-.222
.264-.259
.264-.259
.336-.330
.336-.330
.266
.345
.412
.426
.480
.480
.557
.557
STF086-56
STF112-40
STF138-32
STF164-32
STF190-24
STF190-32
STF250-20
STF250-28
Metric Series Flanged

Self-Threading Inserts
Thread
Part
Size
Number
C E R T I F I E D
ISO9001QS9000
Pilot
Diameter
A
Ref.
STFM2x0.4
STFM2.2x0.45
STFM2.5x0.45
STFM3x0.5
STFM3.5x0.6
STFM4x0.7
STFM5x0.8
STFM6x1
3.10
3.10
3.35
4.32
4.32
4.95
5.89
7.67
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M2xo.4
M2.2x0.45
M2.5x0.45
M3x0.5
M3.5x0.6
M3x0.7
M5x0.8
M6x1
Counterbore
Diameter Depth
E
F
Ref.
Ref.
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Inch Series Flanged

Self-Threading Inserts
Thread
Part
Size
Number
HOLE RECOMMENDATION
.032
.042
.050
.050
.056
.056
.063
.063
HOLE RECOMMENDATION
Flange
Flange
Diameter Thickness Length
B
W
L
0.13
0.10
0.25
4.72
4.72
5.54
6.35
6.35
7.14
9.53
11.13
.141
.172
.219
.250
.270
.270
.375
.375
.51
.51
.64
.76
.76
.89
1.02
1.14
5.80
5.80
7.57
9.02
9.02
9.15
10.27
11.69
Hole
Diameter
C
Thermoset
C
Thermoplastic
Hole
Depth
D
Ref.
3.28-3.23
3.28-3.23
3.96-3.86
5.03-4.93
5.03-4.93
5.84-5.74
6.86-6.71
8.71-8.53
3.24-3.17
3.24-3.17
3.86-3.78
4.93-4.83
4.93-4.83
5.74-5.63
6.71-6.58
8.58-8.38
6.76
6.76
8.76
10.46
10.46
10.82
12.19
14.15
Counterbore
Diameter Depth
E
F
Ref.
Ref.
3.58
3.58
4.37
5.56
5.56
6.35
6.86
9.53
.81
.81
1.07
1.27
1.27
1.27
1.42
1.60
29
Spred-Lok
Fast and easy press-in installation into any type of plastic

Screw expands insert locking it in place permanently
W
MIN. BOSS DIA.
C
STANDARD
INCH SIZES
4-40
6-32
8-32
10-24
10-32
1/4-20
DIMENSIONS
LENGTH
Part Number
A
.005
L
.004
Hole Size
Ref. C
Minimum
Boss Dia.
74115-04
74115-06
74115-2
74115-3
74111-3
74115-4
.166
.199
.230
.262
.262
.326
.188
.250
.313
.375
.375
.500
.156
.188
.219
.250
.250
.313
.332
.398
.460
.524
.524
.652
STANDARD
METRIC SIZES
Thread Size
M3x0.5
M3.5x0.6
M4x0.7
M5x0.8
M6x1
FLANGED
INCH SIZES
HOLE SIZE
RECOMMENDATIONS
DIA.
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Thread Size
DIMENSIONS
HOLE SIZE
RECOMMENDATIONS
DIA.
LENGTH
Part Number
A
0.13
L
0.10
Hole Size
Ref. C
Minimum
Boss Dia.
74117-3
74117-3.5
74117-4
74117-5
74117-6
4.22
5.05
5.84
6.65
8.28
4.78
6.35
7.95
9.53
12.70
3.96
4.78
5.56
6.35
7.95
8.43
10.11
11.68
13.31
16.56
DIA.
DIMENSIONS
FLANGE
LENGTH
DIA.
FLANGE
WIDTH
HOLE SIZE
RECOMMENDATIONS
Part Number
A
.005
L
.004
B
.005
W
.004
Hole Size
Ref. C
Minimum
Boss Dia.
4-40
6-32
8-32
10-24
10-32
1/4-20
74215-04
74215-06
74215-2
74215-3
74211-3
74215-4
.166
.199
.230
.262
.262
.326
.188
.250
.313
.375
.375
.500
.219
.250
.281
.313
.313
.375
.022
.028
.035
.043
.043
.050
.156
.188
.219
.250
.250
.313
.332
.398
.460
.524
.524
.652
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Thread Size
FLANGED
METRIC SIZES
30
MIN. DEPTH =
INSERT LENGTH
PLUS .030 INCH
(0.77 mm)
DIA.
DIMENSIONS
FLANGE
LENGTH
DIA.
FLANGE
WIDTH
HOLE SIZE
RECOMMENDATIONS
Thread Size
Part Number
A
0.13
L
0.10
B
0.13
W
0.10
Hole Size
Ref. C
Minimum
Boss Dia.
M3x0.5
M3.5x0.6
M4x0.7
M5x0.8
M6x1
74217-3
74217-3.5
74217-4
74217-5
74217-6
4.22
5.05
5.84
6.65
8.28
4.78
6.35
7.95
9.53
12.70
5.56
6.35
7.14
7.95
9.53
.56
.71
.89
1.09
1.27
3.96
4.78
5.56
6.35
7.95
8.43
10.11
11.68
13.31
16.56
C E R T I F I E D
ISO9001QS9000
Ideal for prototype shops and engineering staff

Recommended for small jobs or prototype development projects
Complete size range for most applications
Dodge Kits
Ultrasert II
Assortment Kits
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Kits provide design flexibility by

including two insert lengths for
each thread size.
Ultrasert II Metric Assortment Kit Part No.6108
Ultrasert II Inch Assortment Kit Part No. 6107

Size
Part No.
Qty. Size
Part No.
Qty.
Size
#2-56
6035-02BR115
300
#8-32
6035-2BR185
150
M2.5x0.45 6075-2.5BR034 250
#2-56
6035-02BR188
300
#8-32
6035-2BR312
150
#4-40
6035-04BR135
250
#10-32
6041-3BR225
#4-40
6035-04BR219
250
#10-32
#6-32
6035-06BR150
200
#6-32
6035-06BR250
200
Part No.
Qty. Size
Part No.
Qty.
M4x0.7
6075-4BR047
150
M2.5x0.45 6075-2.5BR056 250
M4x0.7
6075-4BR079
150
100
M3x0.5
6075-3BR038
200
M5x0.8
6075-5BR067
100
6041-3BR375
100
M3x0.5
6075-3BR064
200
M5x0.8
6075-5BR111
100
1/4-20
6035-4BR300
50
M3.5x0.6
6075-3.5BR038 200
M6x1
6075-6BR076
50
1/4-20
6035-4BR500
50
M3.5x0.6
6075-3.5BR064 200
M6x1
6075-6BR127
50
Each kit contains commonly used thread sizes. Kits are available in both inch and metric inserts. A slide
chart containing insert data and instructions for hole preparation is included in each kit.
Kits provide design flexibility by

including two insert lengths for
each thread size.
Soldering iron and installation
tips are included for each thread
size.
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Research &
Development
Kits
Inch Research & Development Kit Part No. 6102
Metric Research & Development Kit Part No. 6103
Size
Part No.
Qty. Size
Part No.
Qty.
Size
#4-40
6035-04BR135
100
#10-24
6035-3BR225
50
M2.5x0.45 6075-2.5BR034 100
#4-40
6035-04BR219
100
#10-24
6035-3BR375
50
#6-32
6035-06BR150
100
#10-32
6041-3BR225
#6-32
6035-06BR250
100
#10-32
#8-32
6035-2BR185
50
#8-32
6035-2BR312
50
C E R T I F I E D
ISO9001QS9000
Part No.
Qty. Size
Part No.
Qty.
M4x0.7
6075-4BR047
50
M2.5x0.45 6075-2.5BR056 100
M4x0.7
6075-4BR079
50
50
M3x0.5
6075-3BR038
75
M5x0.8
6075-5BR067
35
6041-3BR375
50
M3x0.5
6075-3BR064
75
M5x0.8
6075-5BR111
35
1/4-20
6035-4BR300
25
M3.5x0.6
6075-3.5BR038
75
M6x1
6075-6BR076
25
1/4-20
6035-4BR500
25
M3.5x0.6
6075-3.5BR064
75
M6x1
6075-6BR127
25
31
Insert Installation & Troubleshooting

HEATED INSERT INSTALLATION
Ultrasonic installation is recommended

for all but the largest insert sizes.
Ultrasonic installation generally results
in very consistent, stress free assemblies with very short cycle times. In
Ultrasonic insertion, the metal insert is
designed to partially enter a cored or
drilled hole in the thermoplastic part.
The vibrating ultrasonic horn contacts
the insert causing the vibration to travel
through to the interface of the metal
insert and the plastic part. Heat generated as a result of the vibration causes
the plastic to effectively mold itself to
the knurls and undercuts of the insert
permanently locking the insert in place.
Inserts may be installed into thermoplastic materials using various sources

of electrically generated energy to heat
the insert above the melting point of the
thermoplastic part. Inserts may be
preheated then pressed into the plastic
part or the insert may be piloted into a
cored or drilled hole in the plastic part
then heated by conduction. Heated
insert installation provides a stress free
assembly and is recommended for very
large insert sizes or when the required
fixturing or noise levels associated with
ultrasonic installation are prohibitive.
INSTALLATION OF EXPANSION
INSERTS
Dodge expansion inserts are easily
installed in both high and low production applications. Dodge manufactures
hand tools and semi-automatic tools
which can be fitted to manual or
powered presses. Part numbers and
description for installation tools can be
found on page 27.
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ULTRASONIC INSTALLATION
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P R O B L E M
POTENTIAL
SOLUTIONS
Insufficient
insert
strength
(pullout,
rotation)
Excessive
flash
on top
surface
Excessive
flash
under
insert
Plastic
boss
bulges or
cracks
Welder
overloads
(cuts out)
Insert
raises above
Insert
top surface Installation
damaged
after top
too
(deformed) installation 1234567890123
noisy
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123456789012345
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123456789012345
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12345678901234
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12345678901234
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12345678901234567890123456789012123456
12345678901234
12345678901234567890123456789012123456
12345678901234
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123456789012345678901234567890121234567
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1234567890123456789012345
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12345678901234567890123456789012123456
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1234567890123456789012345
123456789012345678901234567890121234567
12345678901234567890123456789012123456
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Increase hole diameter

Increase hole depth
Increase boss diameter
Decrease hole diameter
Verify plastic melt
Incorrect fixture design
Countersink/Counterbore hole
Increase amplitude
Increase pressure
Increase weldtime
Decrease downspeed
Increase hold time
Decrease pressure
Decrease amplitude
Decrease weld time
Adjust welder stroke stop
Pre-trigger ultrasonic energy
Tune power supply
Tighten horn, booster, transducer joints
Use more powerful (wattage) welder
Insert
not
Excessive
completely installation
seated
time
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32
C E R T I F I E D
ISO9001QS9000
Testing Terminology
TENSILE STRENGTH
Axial force required to pull the insert out of the parent
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material at least .020 inches (.5mm).
ROTATIONAL TORQUE
Rotational force required to rotate the insert in the

parent material. Note that the hardened steel spacer
only hits on the insert. It is a good comparative
measure of the overall strength of the assembly.
CLAMPLOAD TORQUE
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Rotational force required to rotate the insert in the

hits both the parent material and the insert. Mainly
used as a strength measure for compression limiters.
JACK-OUT TORQUE
Rotational force required to pull the insert out of the
only hits the parent material. This will allow both
rotational and axial forces to be applied simultaneously. The ultimate test of assembly strength.
Results may vary depending on the type of bolt used.
C E R T I F I E D
ISO9001QS9000
33
Fastening Solutions
Fastening solutions for all types of applications

Automotive
Electronics
Medical
Communications
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Its only the beginning
34
C E R T I F I E D
ISO9001QS9000
Custom Insert Designs
Put DODGE
to the test
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Our engineers are fastening specialists who take pride in

their ability to exceed your performance requirements
while minimizing costs. The DODGE database contains
thousands of custom insert designs which may meet
your requirements or we can create a new design specifically for your application. Send Dodge your existing
insert design and we will refine it to increase performance and reduce your costs.
C E R T I F I E D
ISO9001QS9000
35
JACK NUT Threaded Inserts
Standard JACK NUT Threaded Inserts are manufactured of

steel with commercial zinc plating. Brass is available upon
special request (brass requires a 50,000 piece minimum
order).
All JACK NUT threaded inserts can be supplied with coated
flanges. Two types of coatings are offered. The first, called
Raintite, is used for sealing ambient moisture. The second
is a hard plastic coating (PVC) which is used in areas
where additional protection is needed against scratching
(for example, painted panels). Both can also assist with
galvanic corrosion concerns.
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The JACK NUT Threaded Insert is an economical blind

fastener designed for assembly-line use in thin, soft, or
brittle materials. When tightened, the body collapses to
form legs which grip the inside of the mounting surface,
leaving a permanent, reusable threaded insert. Available in
steel, brass, and steel with PVC or Raintite coating.
FEATURES
Fastens in blind holes

Wont distort or deform soft plastics or thin
sheet metals
Fast, inexpensive, and easy to use
Not hole-size sensitive
Fastens securely despite burrs or uneven
substrate
Available withPlastisol coating for sealing
purposes
Suitable for a wide grip range
Can be set with manual or pneumatic tools
Removable
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APPLICATIONS
Toys
Plastic furniture
Spoilers and other aerodynamic devices
License plate brackets
High-lamp stop lights
Mirrors
Air-conditioning condensers
Fuse boxes
Glove compartments
Speaker housings
Decorative trim
Latch mountings
Truck utility compartments
Luggage carriers
Resonators
AND MUCH MORE!
36
C E R T I F I E D
ISO9001QS9000
JACK NUT Threaded Inserts
HOW TO INSTALL
D
h
1. Thread JACK NUT

insert onto mandrel
of installation tool,
then insert all the
way into predrilled
hole until flange is
firmly against
mounting surface.
3. Pass machine screw

2. Fully collapse
through part to be
insert, then remove
fastened, then
installation tool.
tighten until snug.
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DIMENSIONS & SPECIFICATIONS

Body Dia.
(d)
Part
No.
Thread
Size
(in.)
310000
310512
310010
310516
310020
310504
310030
310506
310040
310508
310050
310510
310070
310511
6-32
M4x0.7
6-32
M4x0.7
10-24
M5x0.8
10-24
M5x0.8
1/4-20
M6x1
1/4-20
M6x1
1/4-20
M6x1
0.318
0.318
0.318
0.318
0.382
0.382
0.382
0.382
0.438
0.438
0.438
0.438
0.438
0.438
(mm)
8.08
8.08
8.08
8.08
9.70
9.70
9.70
9.70
11.13
11.13
11.13
11.13
11.13
11.13
Hole Size
min-max
(in.)
0.318-0.330
0.318-0.330
0.318-0.330
0.318-0.330
0.382-0.400
0.382-0.400
0.382-0.400
0.382-0.400
0.438-0.450
0.438-0.450
0.438-0.450
0.438-0.450
0.438-0.450
0.438-0.450
(mm)
8.08-8.38
8.08-8.38
8.08-8.38
8.08-8.38
9.70-10.16
9.70-10.16
9.70-10.16
9.70-10.16
11.13-11.43
11.13-11.43
11.13-11.43
11.13-11.43
11.13-11.43
11.13-11.43
Grip Range
min-max
(in.)
(mm)
0.015-0.187
0.015-0.187
0.187-0.375
0.187-0.375
0.015-0.187
0.015-0.187
0.187-0.375
0.187-0.375
0.015-0.187
0.015-0.187
0.187-0.375
0.187-0.375
0.375-0.500
0.375-0.500
0.38-4.75
0.38-4.75
4.75-9.53
4.75-9.53
0.38-4.75
0.38-4.75
4.75-9.53
4.75-9.53
0.38-4.75
0.38-4.75
4.75-9.53
4.75-9.53
9.53-12.70
9.53-12.70
Length
(L)
Head Height
(h)
Head Dia.
(D)
(in.)
(mm)
(Ref.)
0.468
0.468
0.468
0.468
0.531
0.531
0.531
0.531
0.625
0.625
0.625
0.625
0.625
0.625
11.89
11.89
11.89
11.89
13.49
13.49
13.49
13.49
15.88
15.88
15.88
15.88
15.88
15.88
4SJN
4SJN
4LJN
4LJN
6SJN
6SJN
6LJN
6LJN
8SJN
8SJN
8LJN
8LJN
8XLJN
8XLJN
(in.)
(mm)
(in.)
0.653
0.653
0.841
0.841
0.716
0.716
0.888
0.888
0.731
0.731
0.919
0.919
1.094
1.094
16.59
16.59
21.36
21.36
18.19
18.19
22.56
22.56
18.57
18.57
23.34
23.34
27.79
27.79
0.073
0.073
0.073
0.073
0.073
0.073
0.073
0.073
0.073
0.073
0.073
0.073
0.073
0.073
(mm)
1.85
1.85
1.85
1.85
1.85
1.85
1.85
1.85
1.85
1.85
1.85
1.85
1.85
1.85
Catalog
No.
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JACK NUT Tools
ROTATIONAL PNEUMATIC JACK NUT TOOLS

For the high-volume setting of all sizes of JACK
NUT inserts, these tools set the inserts by
rotation, automatically compensating for
material thickness variations. Reverses for
removal.
CAT. NO.
Weight
LxHxW
Air Pressure
Speed
Torque
C E R T I F I E D
ISO9001QS9000
JNT-7530
1.7 lbs.
8" x 6.5" x 1.5"
90 PSI
2300 RPM
15 in.-lbs.
JNT-7529
2.0 lbs.
9" x 6.5" x 1.5"
90 PSI
750 RPM
50 in.-lbs.
HEAVY-DUTY JACK NUT HAND TOOL

CAT. NO. JNT 2400
Rugged steel tool uses interchangeable screw-rods to set
all sizes. Low grip effort is required, and proper stroke is
preset for positive setting without overtightening.
JNT 2400
Weight: 1.3 lbs.
Dimensions:
101/2" L x 4" H x 3/4" W
37
The WELL-NUT Threaded Insert is a flanged neoprene bushing with a brass machine nut molded into one end. Tightening a conventional machine screw thread in the brass nut
causes the insert to expand, making a secure fastening. Avail-
able in a variety of rubber compounds for a full range of automotive and industrial environments.
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FEATURES
Fastens in blind holes

Helps seal out ambient moisture
Muffles noise
Dampens vibration and shock
Helps prevent galvanic corrosion
Ideal for metal-to-plastic and other mixed
material fastenings
Removable
Installs with conventional tools
Snap-in feature available
Available in several compounds
One-step installation
Can be used in closed end holes
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APPLICATIONS
Windshield wiper motors

Electric panels
Remote-type air cleaners
Radiator mountings
Heating fan motors
Luggage carriers
Sirens and horns
Electronic sensors
Control modules
Windshield washer reservoirs
Inner door panels
Solar panels
Fan motor mounts
Garage door openers
Marine accessories
Fiberglass building panels
Skylights
Transformers
AND MUCH MORE!
38
C E R T I F I E D
ISO9001QS9000
HOW TO INSTALL
D
h
SNAP IN FEATURE
d
2. Pass machine
screw through
part to be
fastened.
3. Tighten until snug.
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1. Place Well-Nut insert

all the way into predrilled hole until flange
is firmly against
mounting surface.
DIMENSIONS & SPECIFICATIONS

Body Dia.
(d)
(in.)
(mm)
Thread
Size
347024
347042
347012
347011
347029
347027
347004
347233
347108
347107
347112
347048
347049
347054
347064
347088
347102
347103
347030
347031
347068
347095
347034
347008
6-32
6-32
8-32
M4x0.7
8-32
M4x0.7
10-24
10-24
10-32
M5x0.8
10-32
10-32
M5x0.8
10-32
10-32
10-32
1/4-20
M6x1
1/4-20
M6x1
1/4-20
1/4-20
5/16-18
3/8-16
C E R T I F I E D
ISO 9001 QS 9000
0.240
0.312
0.312
0.312
0.310
0.310
0.375
0.375
0.375
0.375
0.375
0.375
0.375
0.375
0.375
0.375
0.500
0.500
0.500
0.500
0.500
0.500
0.620
0.750
6.10
7.92
7.92
7.92
7.87
7.87
9.53
9.53
9.53
9.53
9.53
9.53
9.53
9.53
9.53
9.53
12.70
12.70
12.70
12.70
12.70
12.70
15.75
19.05
Hole Size
min.max
(in.)
(mm)
0.250
0.312
0.312
0.312
0.312
0.312
0.375
0.375
0.375
0.375
0.375
0.375
0.375
0.375
0.375
0.375
0.500
0.500
0.500
0.500
0.500
0.500
0.625
0.750
sa
l
Part
No.
6.35
7.92
7.92
7.92
7.92
7.92
9.53
9.53
9.53
9.53
9.53
9.53
9.53
9.53
9.53
9.53
12.70
12.70
12.70
12.70
12.70
12.70
15.88
19.05
Grip Range
min-max
(in.)
(mm)
0.375-0.607
0.015-0.156
0.015-0.156
0.015-0.156
0.015-0.050
0.015-0.050
0.015-0.050
0.030-0.227
0.015-0.192
0.015-0.192
0.312-0.643
0.030-0.227
0.030-0.227
0.312-0.450
0.030-0.227
0.035-0.232
0.015-0.111
0.015-0.111
0.031-0.187
0.031-0.187
0.250-0.457
0.187-0.343
0.015-0.156
0.015-0.437
9.53-15.42
0.38-3.96
0.38-3.96
0.38-3.96
0.38-1.27
0.38-1.27
0.38-1.27
0.76-5.77
0.38-4.88
0.38-4.88
7.92-16.33
0.76-5.77
0.76-5.77
7.92-11.43
0.76-5.77
0.89-5.89
0.38-2.82
0.38-2.82
0.79-4.75
0.79-4.75
6.35-11.61
4.75-8.71
0.38-3.96
0.38-11.10
Length
(L)
(in.)
(mm)
0.981
0.499
0.499
0.499
0.430
0.430
0.562
0.767
0.554
0.554
1.051
0.807
0.807
0.847
0.700
0.665
0.630
0.630
0.829
0.829
1.051
0.801
0.725
1.062
24.92
12.67
12.67
12.67
10.92
10.92
14.27
19.48
14.07
14.07
26.70
20.50
20.50
21.51
17.78
16.89
16.00
16.00
21.06
21.06
26.70
20.35
18.42
26.97
Head Height
(h)
(in.)
(mm)
0.035
0.062
0.052
0.052
0.050
0.050
0.125
0.187
0.036
0.036
0.051
0.187
0.187
0.035
0.080
0.040
0.051
0.051
0.187
0.187
0.051
0.051
0.125
0.187
0.89
1.57
1.32
1.32
1.27
1.27
3.18
4.75
0.91
0.91
1.30
4.75
4.75
0.89
2.03
1.02
1.30
1.30
4.75
4.75
1.30
1.30
3.18
4.75
Head Dia.
(D)
(in.) (mm)
0.554
0.452
0.438
0.438
0.500
0.500
0.562
0.562
0.500
0.500
0.562
0.750
0.750
0.554
0.750
0.562
0.630
0.630
0.750
0.750
0.635
0.635
0.875
1.250
Emhart Fastening
Emhart
Teknologies,
Teknologies
Industrial
Shelton,
Division
CT
Danbury,
Tel. (203)CT924-9341
Tel. (203)
Fax
830-3200
(203) 778-8409
Fax (203) 778-8409
14.07
11.48
11.13
11.13
12.70
12.70
14.27
14.27
12.70
12.70
14.27
19.05
19.05
14.07
19.05
14.27
16.00
16.00
19.05
19.05
16.13
16.13
22.23
31.75
Catalog
No.
(Ref.)
C632
E632
B832
B832
2D832
2D832
A1024
L1024
10S
10S
10SL
G1032
G1032
H1032
J1032
Q1032
1/4S
1/4S
D1420
D1420
J1420
W1420
E51618
A3816
39
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Emhart Teknologies
Industrial Division
50 Shelton Technology Center
P.O. Box 859
Shelton , CT 06484 USA

Dodge Brass Inserts

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Dodge Brass Inserts

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es Fo

Fastening Solutions for Plastics

Creating the Future Worldwide.

develops and delivers solutions for challenging assembly applications.

Fastening Solutions for Plastics

quality improvement and total customer satisfaction.

Insert Selection Guide

Ultrasert II & Ultrasert II Screw-Lock

Designed for high volume production

Most widely accepted and used

Fluted for ultrasonic or heat installation

Designed for installation in straight holes

Same as Ultrasert IV but with flange on the knurled end

Emhart Teknologies Shelton, CT Tel. (203) 924-9341 Fax (203) 778-8409

Insert Selection Guide

Available in two styles to accommodate various applications

Non-threaded bushing to take bolt load instead of the part

Installs without heat or ultrasonics

26 & 27 Flanged & Clinch Expansion

Flanged insert is ideal for electrical contact or fastening terminal connections

28 & 29 Self Threading & Flanged Self Threading

One-piece insert with unique, slotted, expandable outside diameter

Emhart Teknologies Shelton, CT Tel. (203) 924-9341 Fax (203) 778-8409

Dedicated and caring people trained on

Prompt pricing and accurate delivery information

New products are

150,000 square foot

ISO 9001 & QS 9000 Certified

Emhart Teknologies Shelton, CT Tel. (203) 924-9341 Fax (203) 778-8409

Dodge has over 50 factory-trained sales

Broad range of inventory

Applications engineers are ready to evaluate and

Emhart Teknologies Shelton, CT Tel. (203) 924-9341 Fax (203) 778-8409

Vertical flutes and horizontal fins provide superior assembly strength

tensile strength. The gradual external taper optimizes the flow

MIN. BOSS DIA.

INCH INSERT SPECIFICATIONS

HOLE SIZE RECOMMENDATIONS

METRIC INSERT SPECIFICATIONS

HOLE SIZE RECOMMENDATIONS

Emhart Teknologies Shelton, CT Tel. (203) 924-9341 Fax (203) 778-8409

Ultrasert I Test Data

NYLON 6/6 30% G.F.

NYLON 6/6 30% G.F.

Dodge Ultraserts can be installed using ultrasonic equipment

The test data should be considered

(moderate to high production) or thermal installation equipment

The plastic material failed in all

Emhart Teknologies Shelton, CT Tel. (203) 924-9341 Fax (203) 778-8409

Installed ultrasonically or with heat

MIN. BOSS DIA.

INCH INSERT SPECIFICATIONS

METRIC INSERT SPECIFICATIONS

HOLE SIZE RECOMMENDATIONS

HOLE SIZE RECOMMENDATIONS

Emhart Teknologies Shelton, CT Tel. (203) 924-9341 Fax (203) 778-8409

Ultrasert II Test Data

NYLON 6/6 30% G.F.

The test data should be considered

NYLON 6/6 30% G.F.

*Internal thread stripped

Dodge Ultraserts can be installed using ultrasonic equipment

Emhart Teknologies Shelton, CT Tel. (203) 924-9341 Fax (203) 778-8409

Unique internal locking element