Date: Tue, 26 Aug 2008 06:35:52 -0400
Reply-To: Jim Akiba <syncrolist@BOSTIG.COM>
Sender: Vanagon Mailing List <vanagon@gerry.vanagon.com>
From: Jim Akiba <syncrolist@BOSTIG.COM>
Subject: Re: Header bolts broken
In-Reply-To: <c6f.249599e6.35e5310c@aol.com>
Content-Type: text/plain; charset=ISO-8859-1
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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