@Chris don't confuse my meanderings on this thread for any urgency on my part to do anything. It really isn't a priority at the moment and I'd imagine any chemical solution would work better when the weather is warmer and drier anyway.
no, i haven't Simon, can't see anything to cause confusion? - but you helped "throw down the gauntlet" though, otherwise i wouldn't have bit, so i'm up for above challenge wherever it leads now you've "put the fuel on the fire".
Had the same problem with the battery strap insert on my 1280S (and my 1200 DVT before that). Both times fixed by doing what the O/P did and drilled out the bolt and insert. On the 1200 I created a crater getting the insert out, but in both instances fixed a new insert in using a two-pack plastic epoxy kit. I can't remember the name unfortunately but I undoubtedly bought it on ebay. To get the new insert in first I put the plastic mix in the hole/crater. Then I screwed a new insert onto the end of a new bolt having put Vaseline on the whole thread first. Pushed the insert into the hole and after carefully checking the alignment unscrewed the bolt and left it all to set. Both have passed the test of time but I am very careful to be gentle when tightening all those insert threaded bolts - just nip them up.
