Originally Posted by
jdefran
Yes I think they were garbage, some zinc something or other that came with the rack...everything is stainless now. The rusty threads didn't help either. Live and learn as the saying goes
Also, always make sure you are using the correct "nationality" of bolt, too.
I know from certain old British bikes that the dropout eyelets were sometimes tapped for British threads (BSC or even Whitworth). This means that a standard Metric bolt might begin to screw in but will soon tighten excessively and then freeze up to the point of failure - just as you experienced... and even with surprisingly low torque.
If a dropout or frame boss appears to be excessively rusted, you can still commonly "chase" the threads by simply installing the right bolt. But it's good to have a standard metric tap on hand to clean it out first. A 5mm metric tap (and 3mm for Campy dropout adjuster screws) are the most useful to have for bicycle applications and are a VERY inexpensive form of "insurance". Tapping existing bike threads usually requires very little force, so you don't even need a fancy tap handle or a complete die & tap kit.
And, it's a good idea to also lubricate the dropout with an anti-seize lubricant which not only eases the bolt in but tends to also inhibit further rusting. A small tube is usually available at any auto parts store, costs very little, and will suit your bike needs for years... it should be considered a "Must Have" lubricant for use with any alloy quill stems and seatposts, anyway.