Date:         Sun, 3 May 2009 08:44:47 -0700
Reply-To:     Robert Keezer <warmerwagen@YAHOO.COM>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Robert Keezer <warmerwagen@YAHOO.COM>
Subject:      Re: Alternator bracket needs repair
Content-Type: text/plain; charset=iso-8859-1

 
 
 I'll repeat.The upper 8 mm stud hole is OK. The bottom broke off, the PO drilled it offset with about a 7 mm. Your suggestion is to thread with red locktite an aluminum bolt, cut the head off, then drill and retap with a 8 mm in the correct location. 
Or bring to someone who can Tig weld the hole , then drill and tap that.
I know a local machine shop who advertises they weld aluminum heads, but this is the block. That can be done also? Do WBX cases have magnesium like the older air cooled ?
 
Stuff I don't know because I've been driving a inline-four 13 years with a cast iron block.
Thanks for your suggestions. 
Robert
1984 Vanagon
 
 
 
 
 
 
 
 
 


--- On Sat, 5/2/09, David Beierl <dbeierl@ATTGLOBAL.NET> wrote:


From: David Beierl <dbeierl@ATTGLOBAL.NET>
Subject: Re: Alternator bracket needs repair
To: vanagon@GERRY.VANAGON.COM
Date: Saturday, May 2, 2009, 11:15 PM


At 01:02 AM 5/3/2009, Robert Keezer wrote:
>If it was center drilled, I would drill out the old stud. The
>hole  was instead drilled to 7/16 is about a 16th of an inch lower
>that the original.
>Drilling to the proper 8 mm will probably open up the hole to
>outiside the case.

Here's a thought -- clear out the old mess and drill/tap oversize,
thread aluminum rod to fit, install with red (stud-and-bearing)
Loctite and cut off flush.  Then drill/tap to correct size and
location and install stud.

Or open it out and have a welder build it back up with weld metal?

Did you actually mean 7/16?  That's 11+ mm.  5/16 is almost exactly 8
mm (7.9375), though of course the thread is different.  If it really
is 7/16, how about fill it with 7/16 threaded aluminum rod Loctited
in as above, then clean out the remains of the old stud and proceed,
with a Heli-coil or similar if necessary.


  --
David Beierl - Providence RI USA -- http://pws.prserv.net/synergy/Vanagon/
'89 Po' White Star "Scamp"