In a message dated 6/26/00 5:03:51 AM, Puzerewski@email.msn.com writes:

<<  ----- Original Message -----

  From: KiddPanoscha

  To: vanagon@GERRY.VANAGON.COM

  Sent: Sunday, June 25, 2000 8:30 PM

  Subject: [VANAGON] Broken Exhaust Manifold Bolts

  In removing my exhaust manifolds from my 86 Westy Weekender, one bolt broke
off in the head.  Does anyone have any tips on the best way to drill them
out?  I was not planning on removing the head and the position is awkward for
clean drilling.

  Also does anyone know why two pipes are attached with bolts and two with
studs and nuts?

---- >>
Kidd,
I assume you plan to drill out the offending fastener and install an insert
or Helicoil with the engine in place.  It is most important to keep the
drilling and tapping collinear with the original hole and, of course, to not
punch through the bottom of the hole.  I used an accurately made drill guide
which was made from a piece of 1 1/4" stock with two through holes that were
spaced to match the head tapping.  One hole was used to hold the guide to the
head with the good tapping, the other piloted the drill.  Since I was using
Helicoils and had only one shot at doing it right, I also used a similar tap
guide.  I did this work in place on the forward exhaust ports of a 2WD van.
I did not use a right angle drill motor (which would have been nice to have)
but, I did have to use the smallest one I had and I recall needing to shorten
the tap drill a bit.

As far as the stud/capscrew array; the Vanagons I have seen have studs at one
end of a head pipe and capscrews on the other end of the same pipe.  I
believe this arrangement is to ease the installation.  At least one side will
not be cross threaded.
Rich