Date: Tue, 26 Aug 2008 14:20:31 -0700
Reply-To: Scott Daniel - Turbovans <scottdaniel@TURBOVANS.COM>
Sender: Vanagon Mailing List <vanagon@gerry.vanagon.com>
From: Scott Daniel - Turbovans <scottdaniel@TURBOVANS.COM>
Subject: Re: Header bolts broken
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I would sure NOT recommend stainless bolts screwed into the head.
stainless is not 'perfect magic metal' ............it corrodes ( just more
slowly ) and breaks too, and if you ever had to try to drill out a broken
off stainless bolt, you would really be cursing whoever put them in there.
Not fun to drill at all.
that's not the only disadvantage of stainless steel either.
Scott
----- Original Message -----
From: "Cullen Stewart" <cullberly@VERMONTEL.NET>
To: <vanagon@GERRY.VANAGON.COM>
Sent: Tuesday, August 26, 2008 3:24 AM
Subject: Re: Header bolts broken
Fortunately I had no problems with the rear ones. I guess I will be calling
around for a helicoil kit since I would like this going by Saturday. I will
be using stainless on the front bolts now considering the level of corrosion
on them.
Thanks
----- Original Message -----
From: RAlanen@aol.com
To: vanagon@gerry.vanagon.com
Cc: cullberly@vermontel.net
Sent: Tuesday, August 26, 2008 6:12 AM
Subject: Re: Header bolts broken
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)
Frank Condelli & Associates - Vanagon/Vanagon Westfalia Service in the
Ottawa Valley
Vanagon Stainless Steel Exhaust Systems
BusFusion a VW Camper camping event, Almonte, ON, June 12 ~ 15, 2008