Date:         Fri, 16 Jan 2004 21:43:27 -0500
Reply-To:     Dennis Haynes <dhaynes@OPTONLINE.NET>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Dennis Haynes <dhaynes@OPTONLINE.NET>
Subject:      Re: Exaust
Comments: To: RAlanen@aol.com
In-Reply-To:  <157.2bbb093a.2d39336a@aol.com>
Content-Type: text/plain; charset=us-ascii

A trick!
Before drilling, use a grinder or file and get the end of the stud flat.
Then smack the center with a sharp punch. This will keep the drill bit
from wandering. Start with a 1/16" bit. Make sure it is sharp. The OEM
studs are only grade 5.8. The bit will usually follow center. Then work
your way up to the size needed for the 8mm tap or the Heli-Coil. If the
stud is sticking out at all, Mig welding a nut on the end will often set
it loose. The fast heating from welding will cause the stud to expand
faster then the ehad, then quckly cool. The pressure on the threads from
this will often loosen it enough to get the stud to turn out.

Dennis

-----Original Message-----
From: RAlanen@aol.com [mailto:RAlanen@aol.com]
Sent: Friday, January 16, 2004 7:31 AM
To: dhaynes@optonline.net; vanagon@GERRY.VANAGON.COM
Subject: Re: Exaust

In a message dated 15/01/2004 6:45:07 AM Eastern Standard Time,
dhaynes@optonline.net writes:
A right angle pneumatic drill will get in there. BTDT. It is a PITA but
possible. You will need to remove some brackets and hoses but it can be
done.
    Dennis, I've never tried this as I don't own a right angle pneumatic
drill.  HOWEVER, I have recently ordered one from Harbour Freight as
they had a good deal on one and the exchange rate is in my favour these
days.  I bought it with the intention of being able to drill out those
broken exhaust bolt/studs without removing the engine.  I'm still a bit
leary of being able to keep the drill true and not go off centre and
into the block and really screw things up.  One of the problems in doing
this drilling as I have seen is that a lot of those bolt/studs have
become case hardened and are extremely hard to drill.  If your not real
careful the drill will wander off into the block where it has an easier
time drilling.  Still a PITA no matter how you drill it !

Cheers,

Frank Condelli
Almonte, Ontario, Canada
BusFusion <http://members.aol.com/BusFusion/bfhome.htm>  a VW Camper
camping event, Almonte, ON, June 10 ~ 13, 2004
'87 Westy & Lionel Trains
Member: Vanagon List <http://www.vanagon.com/> , LiMBO
<http://www.bcn.net/~limbo/> , IWCCC <http://www.westfalia.qc.ca/>  &
CCVWC <http://www.ccvwc.ca/>
Vanagon/Vanagon Westfalia Service in the Ottawa Valley
STEBRO/Vanagon Stainless <http://members.aol.com/Fkc43/stebro.htm>
Steel Mufflers
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Associates or http://frankcondelli.com