Jim thanks for the lead on these. i found the tap guides at the bottom of this page to be a very interesting idea. http://www.timesert.com/misc.html if gowesty had a set then, they wouldn't have put in a crooked helicoil in for the drain plug on that rebuild they sent me and the drain plug wouldn't leak all the time :). jonathan On Fri, 11 Feb 2005, Jim Thompson wrote: > I agree with Dennis. Although I haven't yet had this particular problem, > I've had a similar situation regarding exhaust port studs/bolts/holes being > stripped. I'm not a fan of the common helicoil in these critical areas, so > I have a suggestion that worked for me. Use Timeserts instead for a beefier > "helicoil" - these are actually a threaded bushing. Since being introduced > to Timeserts in the late 70s, I've rarely used helicoils anymore. They come > as a kit with bushings and the proper tapping tools to do the job. > > Timesert was originally located in Rosemead, CA, just a few miles from where > I grew up and "cut my teeth" on similar Air Cooled VW engine problems such > as this. They're located up near Reno, NV and can be reached at: > > http://www.timesert.com/ > > Jim Thompson > 84 Westfalia 2.1 "Ole Putt" > oldvolkshome@earthlink.net > jim@karmannghia.com > http://www.oldvolkshome.com > *********************** > ----- Original Message ----- > From: "Dennis Haynes" <dhaynes@OPTONLINE.NET> > To: <vanagon@GERRY.VANAGON.COM> > Sent: Thursday, February 10, 2005 7:34 PM > Subject: Re: Broken bolts on 1.9L lower alternator bracket.... > > > > This is not a fun job. The studs are a really tight fit and they are a > > grade 10.9 stud which makes them hard to drill. You will probably need > > good drill bits, a right angle drill, variable speed, EZ outs and a > > torch, (oxy/acetylene). If you do have to completely drill out the > > studs to the threads, you will need a heli-coil. High strength is needed > > here. There is not enough material in the case for oversized studs or > > solid inserts. As for how deep to drill, start with a small drill and > > you will feel where the stud ends. Replacement hardware here must be at > > least grade 10.9 including the washers. The wrong nuts are what probably > > cuased the failure in the first place. Check the bracket carefully. > > These are also prone to cracking. > > > > Dennis > > > > -----Original Message----- > > From: Vanagon Mailing List [mailto:vanagon@gerry.vanagon.com] On Behalf > > Of Paul Guzyk > > Sent: Thursday, February 10, 2005 8:47 PM > > To: vanagon@GERRY.VANAGON.COM > > Subject: Broken bolts on 1.9L lower alternator bracket.... > > > > On my 84 Vanagon the two studs that hold the lower alternator bracket > > to the engine block have broken off (see Bentley page 27.15) > > > > ....and of course they've broken off behind the bracket aka inside > > the engine block. :( > > > > In order to get access to the holes in the block I removed the > > alternator, the metal coolant cross pipe from water pump housing to > > the passenger side head then I removed the oil filler tube from the > > bottom of the block. (The oil filler tube is held on by two 13mm > > nuts, one easy to get at, one not so easy). > > > > Tomorrow I intend to drill out the two broken studs then re-tap them > > with the standard 8mm threads. > > > > How far into the block can I drill? > > If I go too far I assume I will break the water jacket? That > > wouldn't be fun... > > > > Anyone have a better solution? > > > > If you've rigged up some other way to hold the lower alt bracket > > please post photos.... > > > > -Paul > > > |
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