Date:         Thu, 21 Jul 2005 05:04:44 -0700
Reply-To:     Neal Hansen <nhansen@DAKOTACOM.NET>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Neal Hansen <nhansen@DAKOTACOM.NET>
Subject:      Re: Heli-Coil an Engine Oil Drain?
Content-Type: text/plain; charset="iso-8859-1"

You are right. Without the proper jig, drilling the hole straight would be
very difficult. My suggestion would be to install one of those expansion
plugs that are a thick rubber washer sandwiched between two washers. The
inner one being just large enough to fit into the hole and the outer being
slightly larger than the hole, with a tightening screw in the middle.
Usually available at plumbing supply houses. The toggle bolt idea has the
problem of retrieving the toggle when the plug is removed.
Neal
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Date:    Wed, 20 Jul 2005 19:29:31 -0700
From:    Barry Muller <ekab_muller@SBCGLOBAL.NET>
Subject: Heli-Coil an Engine Oil Drain?

Hello,

I have a newer rebuilt 2.1l wasserboxer that while
doing an oil change about 2 years ago I passed a
brain stone and torqued the bolt instead of losening
it.  Bits of helicoil came out that time and during
every oil change since.  I was able to gingerly
install the plug since and got a good seal, until last
week (about 1,000 miles since the last oil change),
now it leaks so bad I can not use the car.  Yes,
painful, but of course I can only blame myself.


Any rate, I've been told that to replace the helicoil
with the next size up is the way to go.  I'm nervous
about doing this because:

A) Never installed a heli-coil before
B) I'm concerned bout drilling the case by hand and
having to keep a hand drill square to the case so I
don't get a cock-eyed hole
C) Concerned about drilling too deep!
D) How do I keep the drill chips from getting into the
engine and slowly machining my newish powerplant
apart?

I'm looking for some real-life experience from those
out there who have gone this route.  I'd like to know
how people solved the issues I listed above and how
long the fix worked for them.

I'f you've used another solution to this problem, that
worked, please let me know about that too.  (No, I'm
not going to use an old spark plug.)

(At this point I think it'd be easier and safer to
install a "molly bolt" (perhaps you knlow these as dry
wall hangers - the ones with the little spring loaded
expanders that deploy after inserting into the hole).
I'd then use a heat-resistant synthetic rubber gasket
and a washer backer to seal the whole bit.)

Thanks in advance

Barry