Don't mess with Mother Volkswagen just buy an exchange rebuilt head or a new
one. No point dealing with the potential of things flying apart on you.

Stan Wilder
www.engineceramics.com

----- Original Message -----
From: "Warren Chapman" <vwsyncroguy@YAHOO.COM>
To: <vanagon@GERRY.VANAGON.COM>
Sent: Monday, August 02, 2004 11:27 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.