You trifle with the Vanagods at your peril.

Cya,
Robert

----- Original Message -----
From: "Roger Sisler" <rogersisler2000@YAHOO.COM>
To: <vanagon@GERRY.VANAGON.COM>
Sent: Friday, January 07, 2005 2:35 PM
Subject: Re: 85 1.9 GL- No.VA head gasket repair shop?

> Hello,I repaired the head gasket on my 1985 westy.It cost $12.I'll tell
> you
> how.First,some background.      I had recently become a vanagon owner for
> the first time, and needed an exhaust pipe replaced on my ride.The 1-3
> exhaust pipe.It had burned a hole at the flange and the po had welded the
> nut onto the stud by mistake in a repair attempt. Had to get it cut off.I
> went to a shop in Takoma Park Md. that seemed to do work on old vw's.I
> asked the owner to replace the pipe. He said"ya know,this will cost you
> more than this thing is worth".I didnt understand what he was talking
> about,as my westy wasnt all that bad.I said go ahead and do it.When he was
> done,I consulted about doing another repair. He said "you better put that
> on the back burner,you have bigger problems". He didnt offer to
> elaborate,and again I didnt understand what he was talking about.I
> left.When I got home ,I discovered that my head gasket was leaking at the
> #3 cylinder.Hummmmmmmmmm.What could I say?A wbx w/155,000 on it.Passed due
> if you ask most people.Anyway,if I couldnt fix it,the engine would be
> fried.Cant replace heads and gasket at that mileage very easily.Not worth
> it w/gaskets costing $75 each.What to do????? I tried every stop leak
> known
> to man-in various combinations.I called manufactures of the stuff for
> suggustions.All said their product would work.Of course they
> didnt.Especially  enthusiastic was the block sealer lady.Lucky I passed
> here.Then I decided on my plan.       I drained the coolant from the
> moter,and jacked the van up on the front right corner to drain any
> remaining coolant away from the #3 cylinder where the leak was.I then used
> an exacto knife to cut  out about 1.5 inches of offending head
> gasket,where
> the leak was.I could stick my pinkie inside the water jacket!It was do or
> die now.I placed a hair dryer on the hole for 2 (two) days and dryed out
> the inside of the water jacket.Bone dry!!I then got 3 tubes of a JB weld
> stick like product called magnum steel($4/Auto Zone,or Walmart).It is good
> to 500 degrees. I cut the puddy into 1 inch pieces and 1 by one mixed
> them.I pressed the puddy into the hole and used a home made tool to reach
> into the water jacket to "mushroom"the puddy on the inside.I overlapped
> the
> hole by about 1 inch on all sides.It look like a big grey wart.Would it
> hold?????If it didnt,I would propably be out of the vanagon business
> before
> I could acquire all the debt from parts that I currently have.Drat!Well I
> doubled the 15 minute drying time to 30 minutes to be sure .I flled the
> cooling system and fired the beast up.No Leakkkkkkk.I couldnt believe
> it ,but it was true.That was over 20,000 ago,and still no leak.I would
> take
> this van anywhere, and never be concerned about a blown head gasket at the
> point where I repaired it.I now have 176,000 on the old wbx,and am going
> for a mileage record.You must remember,my head gasket damage was not
> caused
> by corrosion.A corroded head may be ready to leak in several places,where
> mine only had damage in 1 area.But hey,If you have  an old engine where
> this leak will retire it,why not try.Only cost $12.It is ugly, and
> definatly not kosher,but it will work.Good luck,Roger Sisler.