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Date:         Thu, 15 Jan 2004 06:44:46 -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:  <f3.34ec191f.2d37cbee@aol.com>
Content-type: text/plain; charset=us-ascii

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

-----Original Message----- From: Vanagon Mailing List [mailto:vanagon@gerry.vanagon.com] On Behalf Of Frank Condelli Sent: Thursday, January 15, 2004 5:57 AM To: vanagon@GERRY.VANAGON.COM Subject: Re: Exaust

In a message dated 14/01/2004 1:47:00 PM Eastern Standard Time, LISTSERV@GERRY.VANAGON.COM writes:

Can anyone please tell me how this job can get done with out breaking the bolts and making the job more expensive etc.

No ! There are lots of tricks but NO guarantees. Welding a nut to the end but the bolts at the rear would be almost impossible to do that due to space restrictions and that's the same reason that if those ones break off, the next best thing is to drop the engine. No way you can go there with a drill to drill out the broken studs & bolts. Penetrating liquid can be tried but must be continuously applied and the area heated over a few days to have any success and MOST times the bolts & studs STILL break off so your just wasting time. Something that most shops won't want to do unless you willing to pay for this. DO NOT REMOVE THE HEADS. Your just asking for more problems doing that. If the nuts and bolts break off the best way is drop the engine. Then remove the remaining bolts & studs the best way you can. Then drill out the broken bolts & studs, fit helicoil thread repair inserts to all eight locations then use stainless steel bolts of the proper length at ALL locations. Don't forget abut flat washers, lock washers and the mounting tabs of the push rod tube covers when calculating the length of the bolts. If the bolts are too long you WILL crack the heads and if they are too short you will not get a good seal on the flange. Clean up the exhaust port gasket surface before putting the engine back. Good clean surface here is IMPORTANT to having the gaskets seal well. ALSO, use Loctite Ultra Copper High Temp Silicon Sealant on both sides of the gaskets. To make all this expensive work worthwhile and to not have to visit this scene again sometime in the future think about fitting a stainless steel exhaust system. See my _STEBRO/Vanagon Stainless Steel Exhaust System_ (http://members.aol.com/Fkc43/stebro.htm) webpage for complete details on what I have to offer. 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 Steel Mufflers_ (http://members.aol.com/Fkc43/stebro.htm) _Frank Condelli & Associates_ (http://members.aol.com/Fkc43/busindex.html) or http://frankcondelli.com


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