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Date:         Tue, 26 Aug 2008 06:12:28 EDT
Reply-To:     RAlanen@AOL.COM
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Frank Condelli <RAlanen@AOL.COM>
Subject:      Re: Header bolts broken
Comments: cc: cullberly@VERMONTEL.NET
Content-Type: text/plain; charset="US-ASCII"

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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