How to Install a Crownsert®?
Installing a Crownsert® is fast and repeatable when the hole is prepared correctly and the right tooling is used. The basic process is simple: prepare the bore, cut the thread, install the insert to depth, and swage the crown into the parent material.
Below you'll find the recommended procedure for normal materials (≤187 HB) and hard materials (>187 HB), plus a practical explanation of the tools used during each phase.
What each Crownsert® installation tool does
Step drill tools
A step drill prepares the required bore and counterbore geometry for the Crownsert® in one controlled operation.
In simple terms: it prepares both the hole and the seating area for the insert.
Tap-through tools
A tap-through tool cuts the installation thread in a through hole, where the opening passes completely through the material.
In simple terms: it threads the already-drilled hole so the Crownsert® can be screwed in.
Blind-tap tools
A blind-tap tool cuts the installation thread in a blind hole, where the hole does not pass fully through the material.
Correct drill depth and full thread depth are important for reliable Crownsert® engagement.
Hand installation tools
The hand installation tool is used after drilling and tapping. It combines wrenching and swaging in one tool.
It screws the Crownsert® to the correct depth and then forms the crown into the parent material.
This is the preferred installation method because it reduces tool changes and improves control.
Drive wrench tools
A drive wrench screws the Crownsert® into the prepared and tapped hole before swaging.
Non-locking inserts use 4-point wrenches. Locking inserts use 6-point wrenches.
Drive wrenches are available, but the hand installation tool is preferred because it combines wrenching and swaging.
Swage tools
A swage tool is used after the Crownsert® has been wrenched into position.
It applies downward force to set the external locking feature into the parent material.
Separate swage tools are available, but the hand installation tool is preferred for combined wrenching and swaging.
After-swage gages
An after-swage gage checks the installation after the Crownsert® has been swaged.
It verifies that the insert is fully set and has not been driven too deep.
In simple terms: the swage tool sets the insert; the gage confirms the result.
Removal tools / drills
Removal tools and drills are used when an installed Crownsert® must be removed or replaced.
They drill the swaged locking area to the correct depth so the insert can be backed out safely.
After removal, clean the chips, inspect the hole and replace the insert if the hole remains acceptable.
Installation in Normal Materials (≤187 HB)
Crownserts® are primarily designed for use in aluminium, magnesium, and other lightweight non-ferrous materials. For normal materials up to 187 HB, the installation can normally be completed without pre-broaching the counterbore.
- Step drill the bore. Drill the hole and create the correct counterbore geometry so the Crownsert® has a prepared seat.
- Tap the hole. Cut the required internal thread in the prepared bore. Use the correct tap-through or blind-tap tool depending on the hole type.
- Wrench the Crownsert® into place. Use the hand installation tool to screw the insert into the tapped hole until it reaches the correct depth.
- Swage the Crownsert®. Apply downward force with the installation tool so the crown is formed into the parent material and the insert is mechanically locked.
Installation in Hard Materials (>187 HB)
For harder materials, such as corrosion-resistant steels, titanium, or hardened ferrous materials, an additional broaching step may be required. Broaching prepares the counterbore so the Crownsert® crown or serrations can engage properly without relying only on swaging force.
- Step drill the bore. Drill the hole and create the counterbore that will seat the Crownsert®.
- Tap the hole. Cut the required internal thread so the Crownsert® can be installed to the correct depth.
- Pre-broach the counterbore. Use the appropriate broaching tool to create the crown or serration space in the harder parent material.
- Wrench the Crownsert® into the hole. Use the hand installation tool to screw the insert into the prepared thread until it reaches the specified depth.
- Swage the Crownsert®. Apply downward force so the crown is fully seated and the insert is mechanically locked in the bore.
Our installation tool
Other manufacturers often use separate tools for the wrenching and swaging operations. We have developed a hand installation tool that combines both operations in one tool.
First, the tool drives the Crownsert® into the tapped hole. Then, using the same tool, downward force is applied to swage the crown into the parent material. This reduces tool changes and makes the installation process more repeatable.
Compatibility between tools
Below we explore the compatibility options between the installation tool, broaching tool and step drill.
Locking Crownserts
| Crownsert Installation Tool No° | Crownsert Wobble Broach No° | Crownsert Step Drill No° |
|---|---|---|
| CSTL02 | CSBT02W | CSD0113 |
| CSTL04 | CSBT04W | CSD0140 |
| CSTL06 | CSBT06W | CSD0166 |
| CSTL08 | CSBT08W | CSD0191 |
| CSTL1024 | CSBT1024W | CSD0221 |
| CSTL1032 | CSBT1032W | CSD0221 |
| CSTL420 | CSBT420W | CSD0281 |
| CSTL428 | CSBT428W | CSD0281 |
| CSTL518 | CSBT518W | CSD0343 |
| CSTL524 | CSBT524W | CSD0343 |
| CSTL616 | CSBT616W | CSD0404 |
| CSTL624 | CSBT624W | CSD0404 |
| CSTL714 | CSBT714W | CSD0468 |
| CSTL720 | CSBT720W | CSD0468 |
| CSTL820 | CSBT820W | CSD0531 |
| CSTL813 | CSBT813W | CSD0531 |
| CSTL912 | CSBT912W | CSD0625 |
| CTSL918 | CSBT918W | CSD0625 |
| CSTL1011 | CSBT1011W | CSD0702 |
| CSTL1018 | CSBT1018W | CSD0702 |
| CSTL1210 | CSBT1210W | CSD0836 |
| CSTL1216 | CSBT1216W | CSD0836 |
Non-Locking Crownserts
| Crownsert Installation Tool No° | Crownsert Wobble Broach No° | Crownsert Step Drill No° |
|---|---|---|
| CST02 | CSBT02W | CSD0113 |
| CST04 | CSBT04W | CSD0140 |
| CST06 | CSBT06W | CSD0166 |
| CST08 | CSBT08W | CSD0191 |
| CST1024 | CSBT1024W | CSD0221 |
| CST1032 | CSBT1032W | CSD0221 |
| CST420 | CSBT420W | CSD0281 |
| CST428 | CSBT428W | CSD0281 |
| CST518 | CSBT518W | CSD0343 |
| CST524 | CSBT524W | CSD0343 |
| CST616 | CSBT616W | CSD0404 |
| CST624 | CSBT624W | CSD0404 |
| CST714 | CSBT714W | CSD0468 |
| CST720 | CSBT720W | CSD0468 |
| CST813 | CSBT820W | CSD0531 |
| CST820 | CSBT813W | CSD0531 |
| CST912 | CSBT912W | CSD0625 |
| CTSL918 | CSBT918W | CSD0625 |
| CST1011 | CSBT1011W | CSD0702 |
| CST1018 | CSBT1018W | CSD0702 |
| CST1210 | CSBT1210W | CSD0836 |
| CST1216 | CSBT1216W | CSD0836 |
Frequently Asked Questions
What does 187 HB mean?
187 HB is the Brinell hardness threshold used here to distinguish normal materials from hard materials. In normal materials, the Crownsert® can usually be installed using the standard four-step process. Above 187 HB, pre-broaching may be required before swaging.
Do I always need a broaching tool?
No. In normal materials, broaching is typically not required. In harder materials, broaching prepares the counterbore so the Crownsert® crown or serrations can engage properly during the final locking operation.
What is the difference between wrenching and swaging?
Wrenching screws the Crownsert® into the tapped hole to the correct depth. Swaging is the final locking operation, where downward force forms the crown into the parent material so the insert is securely seated.
Why use the combined hand installation tool?
The combined hand installation tool reduces tool changes by performing both the wrenching and swaging operations. This makes the installation faster, cleaner, and more repeatable.