Date: Tue, 4 Jun 2013 05:32:17 -0700
Reply-To: Stephen Grisanti <bike2vcu@YAHOO.COM>
Sender: Vanagon Mailing List <vanagon@gerry.vanagon.com>
From: Stephen Grisanti <bike2vcu@YAHOO.COM>
Subject: Re: Exaust system replacement
In-Reply-To: <0976DD74-46AD-47DB-B8E3-67D5C9981DF0@aol.com>
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All good advice. I did this a couple of years ago and wound up breaking off two studs, both uppers. One on the driver's side rear and the other on the passenger side front. The second one I got out with PB Blaster, heat and a pipe wrench. The other eventually required head removal and the services of a machine shop.
You'll probably wind up removing more nearby parts than you anticipated simply because, while you can see and even reach the target parts, you can't get any muscle on them without making more space. Bag and label the stuff you take off and need to reinstall. Photos will help because you WON'T remember everything. Trust me on this.
I also found handy a Dremel tool with cutting wheel that let me slice through some troublesome nuts and remove them to salvage the stud and threads. I began with a Sawzall to cut away the big chunks of exhaust just to get them out of the way.
If you do get a shop to quote you on the job be sure to ask about broken studs and the price for additional work. You might be shocked at the resulting number.
It's a challenging job. Really smart people like me wait for humid, awful mid-summer to arrive in Virginia and then have to perform the work in a gravel driveway. It only adds to the joy. Good luck!
Stephen
--- On Tue, 6/4/13, Frank Condelli <RAlanen@AOL.COM> wrote:
From: Frank Condelli <RAlanen@AOL.COM>
Subject: Re: Exaust system replacement
To: vanagon@GERRY.VANAGON.COM
Date: Tuesday, June 4, 2013, 5:32 AM
See my <http://www.frankcondelli.com/exhaustinstall.htm> for some good tips. This document was written for the Stainless Steel exhaust systems I used to sell but some of it is still relevant. As for the removal of the studs and bolts at the exhaust ports, this is probably the most challenging job you will come across on these vans, there is no one way to get them out easily, each case will differ. Take your time and be patient as each one that breaks off will give you grief in trying to drill and tap that hole to get a new connection. Use of heat from a oxy acetylene torch or MAPP gas propane torch is helpful sometimes, heat the area of the head around the stud or bolt, apply liberal amounts of release-all or try Freeze it, shock therapy by hitting the end may also help, double nut the studs will give a better grip on them than vice grips, or welding a nut to the stud, the nuts can be cut off with a die grinder to get them off the studs
if they have rusted to the point they no longer fit any wrench size, but then your still left with the stud to remove as I advocate getting all the studs out and using only bolts in all locations to install the new headers, it makes life easier in the long run. Then, if you do break any off then your into drilling and tapping and that's an entirely different set of problems. Cut the remaining stud/bolt off flush with the exhaust port, drill a small, 1/8", pilot hole with a SHARP high quality drill bit, then enlarge the hole for a 8mm tap or an 8mm Time-Sert if the hole gets damaged beyond use for 8mm threads. Beware to not drill the hole deeper than it was originally or you will drill into the water jacket of the head and it will leak and that's the end of that head. The ports at the front are easy the ones at the rear you will need to do some acrobatics to do them if needed, removal of some of the ancillaries in the way may be needed, an angle
drill with cut off drill bits will be needed and lot's of luck and patience and in some cases you may have to lower the engine to get in there easily. AND, check the archives as this subject has been covered by myself and many others. It's not fun and I will be doing one for a customer next week right after BusFusion, LUCKY ME ! I will be sure to have a lot of Tequila at BusFusion to prepare myself, you should do the same ! Now if I have not discouraged you go at it OR find a GOOD Vanagon mechanic who has done this job before and is WILLING to do it for you for well deserved CASH !
On 2013-06-04, at 12:00 AM, Automatic digest processor <LISTSERV@GERRY.VANAGON.COM> wrote:
> Hi all Vanagonians,
>
> I'm thinking of replacing the complete exhaust system for my 1985 Vanagon, by purchassing the parts from the Busdepot. Has anyone done this lately, what should I watch out for. My main worry is the removing of the stud nuts, without twisting off the studs. Should I remove the alternator and waterpump for easier access.
> Any help is appreciated.
Cheers,
Frank Condelli
Almonte, Ontario, Canada
'87 VW Westy, '00 Kawasaki 250 Sherpa, "98 Ducati 750 Monster & Lionel Trains (Collection for sale)
Frank Condelli & Associates - Vanagon/Vanagon Westfalia Service in the Ottawa Valley
BusFusion a VW Camper camping event, Almonte, ON, June 06 ~ 09, 2013
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