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Date:         Mon, 26 Jun 2000 10:26:09 EDT
Reply-To:     JKrevnov@aol.com
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Rico Sapolich <JKrevnov@aol.com>
Subject:      Re: Broken Exhaust Manifold Bolts
Comments: To: Puzerewski@email.msn.com
Content-Type: text/plain; charset="US-ASCII"

In a message dated 6/26/00 5:03:51 AM, Puzerewski@email.msn.com writes:

<< ----- Original Message -----

From: KiddPanoscha

To: vanagon@GERRY.VANAGON.COM

Sent: Sunday, June 25, 2000 8:30 PM

Subject: [VANAGON] Broken Exhaust Manifold Bolts

In removing my exhaust manifolds from my 86 Westy Weekender, one bolt broke off in the head. Does anyone have any tips on the best way to drill them out? I was not planning on removing the head and the position is awkward for clean drilling.

Also does anyone know why two pipes are attached with bolts and two with studs and nuts?

---- >> Kidd, I assume you plan to drill out the offending fastener and install an insert or Helicoil with the engine in place. It is most important to keep the drilling and tapping collinear with the original hole and, of course, to not punch through the bottom of the hole. I used an accurately made drill guide which was made from a piece of 1 1/4" stock with two through holes that were spaced to match the head tapping. One hole was used to hold the guide to the head with the good tapping, the other piloted the drill. Since I was using Helicoils and had only one shot at doing it right, I also used a similar tap guide. I did this work in place on the forward exhaust ports of a 2WD van. I did not use a right angle drill motor (which would have been nice to have) but, I did have to use the smallest one I had and I recall needing to shorten the tap drill a bit.

As far as the stud/capscrew array; the Vanagons I have seen have studs at one end of a head pipe and capscrews on the other end of the same pipe. I believe this arrangement is to ease the installation. At least one side will not be cross threaded. Rich


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