In a message dated 10/11/2001 3:13:46 PM Eastern Daylight Time, 
LISTSERV@GERRY.VANAGON.COM writes:

> exhaust leak and leaking heads??
> 
       Jenny, If you plan to keep that '87 Westy of yours I highly recommend 
that you install a stainless steel system.  The best scenario is to get the <A HREF="http://members.aol.com/Fkc43/stebro.htm">
STEBRO/Vanagon Stainless Steel Muffler & J-pipe.</A>  Please click on the 
highlighted link which will take you to our website where you will find 
complete technical details, pictures of our muffler and j-pipe, pricing, 
ordering instructions, and customer reviews.  Our Muffler and J-pipe are 
guaranteed for life.  There is a 5% Vanagon List member discount which you 
must ask for when placing your order.  
       For the header pipes I recommend you go with the DANSK stainless steel 
ones that only <A HREF="http://www.busdepot.com/">The Bus Depot - Discount VW Parts - Main Menu</A> sells.  These 
DANSK made header pipes do not have the flanges or the support brackets made 
from stainless, only the tubing is stainless.  There is no warranty from 
DANSK but the Bus Depot will give you a six month warranty.  I have had a set 
of these on my '87 Westy since June of 2000 when they first became available. 
 I have also installed many sets on my customer's Vanagons along with the 
STEBRO/Vanagon Stainless Steel Muffler & J-pipe.  This combination is 
performing perfectly in all cases.  I believe The Bus Depot will give you a 
5% Vanagon List member discount which you must also ask for.
       The CAT you can get through most local quality auto parts or from the 
Bus Depot if you need it.  
       The cast iron collector piece can be had from the Bus Depot for a good 
price.
       The header studs/bolts that your mechanic is speaking of is a known 
problem.  Most always some if not all of them will break and require drilling 
and tapping and sometimes helicoil insertion to get new treads back that will 
hold your header securely to the heads without leaking.  I recommend using 
bolts in all locations instead of studs.  I have in some instances enlarged 
the threads in the head to take 1/2" bolts instead of the 14 mm that are 
original.  If you use the larger bolts you will need to enlarge the holes in 
the header flanges and gaskets.  In all cases make sure the holes in the 
flanges are a bit larger than the bolts your using so there will be no 
lateral stress on the flange.  Use stainless steel bolts, flat washers and 
lock washers with anti-sieze compound on the bolt threads.  If the bolts 
break at the front of the engine then they can be repaired without removing 
the heads or engine.  BUT, if the bolts break at the back of the engine then 
the heads or engine will have to be removed to do the repair as there is 
virtually no room there to work effectively.  
       This is now a good time to mention your possible head leak problem.  
If it is found that the heads are leaking, which is VERY common, then it may 
be best to remove the engine and have the head leak problem repaired and do 
the header bolt repair at the same time.  It would be best in this instance 
to have helicoils inserted in all eight locations of the header flange 
stud/bolts.
       This would be a good time to make sure the cooling tins that cover the 
push rod tubes are in good condition as they are attached to the header 
flange bolts and it would not be economical to have to go under there again 
to remove and install those header flange bolts again to get those cooling 
tins replaced.
       Good luck with your project and if I can be of any further assistance 
please contact me.

Peace�

Frank Condelli
Almonte, Ontario, Canada
<A HREF="http://members.aol.com/BusFusion/bfhome.htm">BusFusion</A> a VW Camper camping event, Almonte, ON, May 30, 31, June 1, 2, 2002
'87 Westy & Lionel Trains
Member: <A HREF="http://www.vanagon.com/">Vanagon List</A>, <A HREF="http://www.bcn.net/~limbo/">LiMBO</A>, <A HREF="http://www.westfalia.qc.ca/CIW_English.asp">IWCCC</A> & Capital City VW Club 
Vanagon/Vanagon Westfalia Service in the Ottawa Valley
<A HREF="http://members.aol.com/Fkc43/stebro.htm">STEBRO/Vanagon Stainless Steel Mufflers</A> �
<A HREF="http://members.aol.com/Fkc43/busindex.html">Frank Condelli & Associates</A> or http://frankcondelli.com

 

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