Date:         Tue, 21 Dec 1999 05:01:08 PST
Reply-To:     James Ruch <jpeterruch@HOTMAIL.COM>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         James Ruch <jpeterruch@HOTMAIL.COM>
Subject:      HEADSTUD HORROR!
Content-Type: text/plain; format=flowed

Don't read this with the lights out... it could happen to you!

Twenty some hours into a both-sides head gasket job (including resurfacing
of the old mating surfaces etc)... first side done... going into the final
torque sequence (anicipating the sound of the engine firing on the first
attempt)... at the specified 37 ft. lbs.... out of the dark and gloomy
nothing... PING!! and my wrench goes slack.  I knew it wasn't good.

I had noted that the head studs didn't look so good and that if I ever did
this job again, I might have to replace them.  One of them (number 2 in the
torque sequence) failed.  It broke way down near the crankcase... before any
threads that might be there.

I am thinking about threading the hole in the head that the stud passes
through and simply plugging it.

Questions:

1.  What are the chances of my getting away with this "plug plan".

2.  If I have to replace the stud(s), do I have to split the crankcase?

3.  "To me -- to me -- why do these things always happen to me?"

Thanks for any help anyone can provide.

Still smiling (amazingly)

Jim Ruch
'85 Weekender; "Snugvagon"
Alfred, NY
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