Warren,

Here's your chance to see just how good JB Weld(brand of epoxy) is.  It's supposed to work on engine
cracks, I've used it in the past on the pits(head gasket sealing area) in watercooled cylinder
heads.  After you drill out the broken bolts, it'll cost about $5 and a few minutes of your time.

BTW, after trying to drill out many broken easyouts I found it's alot easier to just drill the bolt
out all the way...it takes time(sometimes an hour)  but the bolt is softer metal than the easyout,
and I can't remember easyouts working very often, and when they break off then you are really stuck.
Just get the best drill bit you can buy and keep it cool while you're drilling.

There are alumimun welders who are really good at this kind of thing, whether the weld works depends
alot on how much shrinkage the weld causes, and it's location.  And they usually want the engine out
of the car.  I've had it done on aircooled Bug engines successfully.  You need to know the
composition of the case/housing material(aluminum/magnesium??).

JC

----- Original Message -----
From: "Warren Chapman" <vwsyncroguy@YAHOO.COM>
To: <vanagon@GERRY.VANAGON.COM>
Sent: Monday, August 02, 2004 9:27 AM
Subject: Cylinder Heads - can they be welded ??

> Really have a Pandora's box....here....
>
> Started with a Temp sender not working on 86 2.1L...diagnosed no continuity
> (ground) between the aluminum thermostat/temp sender housing and the head.
> Thought I'd just remove the housing, clean up the bolt threads and re-
> install...
>
> Bolts would not come out.....both frozen and sheered off in the head.
> While trying to back out the bolts by drilling and using an easy-out, I
> cracked  the aluminum head with the easy-out at the upper bolt hole. Pretty
> big crack at the top of the bolt hole/thermostat mount.
>
> Anyone have any luck tig welding on Vanagon heads???
>
> Opinions?....will I be able to weld/repair this head or will have have to
> put on another head.
>
> Warren C.