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Date:         Mon, 8 Nov 2004 06:08:31 -0500
Reply-To:     Dennis Haynes <dhaynes@OPTONLINE.NET>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Dennis Haynes <dhaynes@OPTONLINE.NET>
Subject:      Re: head stud frustration
Comments: To: Dyer Lytle <dyer@LPL.ARIZONA.EDU>
In-Reply-To:  <418F0848.2080904@lpl.arizona.edu>
Content-type: text/plain; charset=us-ascii

Are they weak from corrosion or were they overheated or overstretched? If they are failing due to overheating, then the case has to be carefully measured to make sure it is still straight.

My tick is to weld nuts on the piece remaining using a MIG welder. The heat from welding also helps to loosen the stud.

Dennis

-----Original Message----- From: Vanagon Mailing List [mailto:vanagon@gerry.vanagon.com] On Behalf Of Dyer Lytle Sent: Monday, November 08, 2004 12:47 AM To: vanagon@GERRY.VANAGON.COM Subject: head stud frustration

Hi all,

I have been very slowly rebuilding the 1.9 water boxer out of my '84. The failure that triggered the rebuild was a broken head stud. I had hoped the other studs would be OK but, alas, it is not to be. While torqueing down the 1-2 cylinder head another head stud let go. I decided I should replace all the head studs since they can't be trusted. Removing the old head studs is proving to be a mess because they are all in a weakened condition and I have broken a few more trying to remove them. I have read the archives and have soaked them in penetrating oil, struck them sharply on the end with a hammer, and am using an impact wrench to remove them. Unfortunately, the shanks are weak and break. One broke near the base and will be hard to remove. Has anyone had any luck drilling the bottom ends of these things out? Any recommendations?

Thanks,

-Dyer Lytle in Tucson


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