Date: Tue, 26 Aug 2008 17:12:42 -0400
Reply-To: Cullen Stewart <cullberly@VERMONTEL.NET>
Sender: Vanagon Mailing List <vanagon@gerry.vanagon.com>
From: Cullen Stewart <cullberly@VERMONTEL.NET>
Subject: Re: Header bolts broken
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The front bolts are the problem. The studs in the rear were easy. I am
getting a helicoil kit tomorrow and am going to drill and fill the problem
bolts accordingly and replace them with stainless. Do you know of a place
nationally that I can get stainless M8 1.25 bolts for the replacement?
thanks, Cullen
----- Original Message -----
From: "Jim Akiba" <syncrolist@BOSTIG.COM>
To: <vanagon@GERRY.VANAGON.COM>
Sent: Tuesday, August 26, 2008 6:35 AM
Subject: Re: Header bolts broken
> Another great way for pulling steel studs out of Aluminum quick and
> easy is to TIG weld a bolt to the remaining portion and then twist it
> out. You get heat + you get a new head which are both really helpful
> at the same time. The only problem is you need to have a TIG welder
> AND be able to weld in funky positions which unless you have a finger
> amptroller is hilarious, knees, other people etc..
>
> Yeah sucks but definitely not the worst I think. You're surrounded by
> lot's of folks with lot's of worse in vanagonland so the competition
> is pretty stiff ha.
>
> Do you have a drill that is low clearance enough for it as per Frank's
> suggestion?
>
> Jim Akiba
>
> On Tue, Aug 26, 2008 at 6:12 AM, Frank Condelli <RAlanen@aol.com> wrote:
>> In a message dated 25/08/2008 10:12:35 P.M. Central Standard Time,
>> LISTSERV@GERRY.VANAGON.COM writes:
>>
>> Well, that's sort of NORMAL ! I have them break off frequently
>> no
>> matter how careful I am. So, now you will have to get out the drill and
>> drill
>> bits and start drilling them out and insert Helicoils. You will need to
>> source 35mm long Helicoils or stack the common short ones. The ones at
>> the
>> front are not that hard to attack with a small air drill but the ones at
>> the back
>> - WHOA !!!! I have a very small right angled air drill and a whole
>> series
>> of cut off drill bits to do them ! Time consuming for sure but can be
>> done
>> with the engine in the van. The other option is to remove the heads but
>> then
>> your into a complete reseal job ! NO FUN ! Get the surface good and
>> flat
>> before hitting the broken off bolt with a centre punch and try to get it
>> as
>> centred as possible. Start with a 1/8" drill bit and be careful not to
>> break
>> it off ! Then go up in size maybe 2 or 3 sizes so that you can rock the
>> bit
>> back and forth to get the hole centred if it was not at the beginning.
>> Eventually you will get to the proper size bit that will allow you to
>> run a tap in
>> there for the Helicoil. Be careful to not drill past the original depth
>> or
>> you WILL go into the coolant chamber and then the head is scrap metal !
>> Use
>> only carbide drill bits !! Keep the drill bit in the bolt and DON'T let
>> it
>> wander off into the aluminium (NOT EASY) especially at the rear !
>>
>>
>>
>>>>>>>The worst has happened. After very patiently removing the nuts and
>> bolts =
>> on my wbx I twisted 2 off and still have 1 to go. They are flush with =
>> the head and have nothing to grab onto. What are my options with out =
>> removing the head. They are obviously not grade 5 or 8, but good old =
>> garbage grade 2 considering they twisted off with a minimum amount off =
>> force. Is it possible to helicoil these while in the van?<<<<<<<<<
>>
>>
>>
>>
>>
>> Cheers,
>>
>> Frank Condelli
>> Almonte, Ontario, Canada
>> '87 Westy & Lionel Trains (_Collection for sale_
>> (http://members.aol.com/Fkc43/trainsal.htm) )
>> _Frank Condelli & Associates_
>> (http://members.aol.com/Fkc43/busindex.html)
>> - Vanagon/Vanagon Westfalia Service in the Ottawa Valley
>> _Vanagon Stainless Steel Exhaust Systems_
>> (http://members.aol.com/Fkc43/exhaust.htm)
>> _BusFusion_ (http://members.aol.com/BusFusion/bfhome.htm) a VW Camper
>> camping event, Almonte, ON, June 12 ~ 15, 2008
>>
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