Date: Fri, 11 Feb 2005 17:53:11 -0500
Reply-To: Dennis Haynes <dhaynes@OPTONLINE.NET>
Sender: Vanagon Mailing List <vanagon@gerry.vanagon.com>
From: Dennis Haynes <dhaynes@OPTONLINE.NET>
Subject: Re: Broken bolts on 1.9L lower alternator bracket....
In-Reply-To: <003901c5105e$40b3e9b0$2bcaa8c0@Jimbo>
Content-type: text/plain; charset=US-ASCII
Timeserts are wonderful. But they do require a larger drill and tap
size. For exhaust, they also have the disadvantage that a stud or bolt
can seize into them. A Heli-Coil properly installed will be much
stronger than the original threaded hole. You can even get them in
locking designs to keep a bolt or stud in place. If needed, you can
remove them, even by un-coiling and replace them. The case near the
alternator mount does not have much room there so the Heli-coil is my
choice.
Dennis
-----Original Message-----
From: Jim Thompson [mailto:jim@karmannghia.com]
Sent: Friday, February 11, 2005 12:22 PM
To: Dennis Haynes; vanagon@GERRY.VANAGON.COM
Subject: Re: Re: Broken bolts on 1.9L lower alternator bracket....
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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