Date:         Sun, 2 Aug 1998 09:40:27 EDT
Reply-To:     SyncroHead@AOL.COM
Sender:       Vanagon Mailing List <Vanagon@vanagon.com>
From:         SyncroHead@AOL.COM
Subject:      Re: Broken exhaust stud....  bummed... need ideas
Comments: To: Paulc@SNET.NET, Vanagon@VANAGON.COM
Content-type: text/plain; charset=US-ASCII

In a message dated 98-08-01 10:40:35 EDT, Paulc@SNET.NET writes:

> Has any broken a stud while removing the exhaust system on a 1986
>  Watercooled?

Yes.  I had two broken bolts in a used engine I purchased.  Luckily I noticed
this before I installed the engine.  I spent nearly two weeks trying Liquid
Wrench, drills, taps, and various forms of "easy-outs".  None of which were
easy!  None of which got the stud out!

>  Is there a way to extract this in the vehicle?

Finally, I took the whole engine to a machine shop here in southern California
that specializes in removing broken studs/taps/bits/outs, etc.  Luckily, they
were able to place thewhole engine in their jig.  They did a really
professional job removing the whole mess with a LASER and then installing a
stainless steel threaded "insert".
I surely hope you fair better than I, but I would thinktwice before investing
too much time before talking to a professional at this.

Good luck,
Jim Davis