What you need is a "Helicoil", he'll get a kit that contains a drill, tap, a
funny spring and a key to put the funny spring in the new hole he's drilled
and tapped. The spring is actually the new threads. No real harm done and it
could possibly be stronger. Plus, most kits come with several springs/coils
so you have one for next time!

Joe

----- Original Message -----
From: "Bradley Flubacher" <flubach@HOME.COM>
To: <vanagon@GERRY.VANAGON.COM>
Sent: Tuesday, October 24, 2000 10:42 PM
Subject: stripped stud hole

> I just successfully stripped out a threaded hole in a head that holds the
> exhaust header on my vanagon.  My father-in-law is very knowledgable about
> this sort of thing so I'll be asking him what to do.
>
> I suspect I'll have to tap it out at the next larger size and get a new
> sized stud to match.
>
> This is the stud that is right under the water pump.  (at a glance, that's
> what it looked like from underneath)  I had to remove the studs so I could
> take off the header without removing the pump.  I foolishly overtightened
> the stud.  Anyhow, I say all this because I want to retain the ability to
> remove the stud if I need to again... although I don't anticipate ever
> needing to replace this pipe again.  Worse case I could epoxy/JB
> weld/whatever it into the head.  I don't like that idea at all though.
>
> I notice that one of the PO's had a stud replaced.  For that reason it
looks
> as though I'm going to have to enlarge on of the holes on the front
header.
> It won't fit on the way it should.
>
> Needless to say, replacing my exhaust has turned into more that just a
quick
> evening job.  :)  Luckily I have a sense of humor!!
>
> Bradley Flubacher
> State College, PA
>