Hi Dennis -

Valid point taken as I haven't had the displeasure of tackling the
Alternator Bracket studs....yet (maybe I'm lucky or on borrowed time).  I
will keep that in mind, as should Jonathan.

As of yet (after 30+ years), I have yet to have a bolt seize in a Timesert,
but you're right, it could happen.  I generally use Timserts in a situation
involving studs (and their holes they go into), rather than bolts (probably
could count on one hand).

Thanks for your reply :-)

Jim Thompson
84 Westfalia 2.1 "Ole Putt"
oldvolkshome@earthlink.net
jim@karmannghia.com
http://www.oldvolkshome.com
***********************
----- Original Message -----
From: "Dennis Haynes" <dhaynes@optonline.net>
To: "'Jim Thompson'" <jim@karmannghia.com>; <vanagon@GERRY.VANAGON.COM>
Sent: Friday, February 11, 2005 2:53 PM
Subject: RE: Re: Broken bolts on 1.9L lower alternator bracket....

> Timeserts are wonderful. But they do require a larger drill and tap
> size. For exhaust, they also have the disadvantage that a stud or bolt
> can seize into them. A Heli-Coil properly installed will be much
> stronger than the original threaded hole. You can even get them in
> locking designs to keep a bolt or stud in place. If needed, you can
> remove them, even by un-coiling and replace them. The case near the
> alternator mount does not have much room there so the Heli-coil is my
> choice.
>
> Dennis
>
> -----Original Message-----
> From: Jim Thompson [mailto:jim@karmannghia.com]
> Sent: Friday, February 11, 2005 12:22 PM
> To: Dennis Haynes; vanagon@GERRY.VANAGON.COM
> Subject: Re: Re: Broken bolts on 1.9L lower alternator bracket....
>
> I agree with Dennis.  Although I haven't yet had this particular
> problem,
> I've had a similar situation regarding exhaust port studs/bolts/holes
> being
> stripped.  I'm not a fan of the common helicoil in these critical areas,
> so
> I have a suggestion that worked for me.  Use Timeserts instead for a
> beefier
> "helicoil" - these are actually a threaded bushing.  Since being
> introduced
> to Timeserts in the late 70s, I've rarely used helicoils anymore.  They
> come
> as a kit with bushings and the proper tapping tools to do the job.
>
> Timesert was originally located in Rosemead, CA, just a few miles from
> where
> I grew up and "cut my teeth" on similar Air Cooled VW engine problems
> such
> as this.  They're located up near Reno, NV and can be reached at:
>
> http://www.timesert.com/
>
> Jim Thompson
> 84 Westfalia 2.1 "Ole Putt"
> oldvolkshome@earthlink.net
> jim@karmannghia.com
> http://www.oldvolkshome.com
> ***********************
> ----- Original Message -----
> From: "Dennis Haynes" <dhaynes@OPTONLINE.NET>
> To: <vanagon@GERRY.VANAGON.COM>
> Sent: Thursday, February 10, 2005 7:34 PM
> Subject: Re: Broken bolts on 1.9L lower alternator bracket....
>
>
> > This is not a fun job. The studs are a really tight fit and they are a
> > grade 10.9 stud which makes them hard to drill. You will probably need
> > good drill bits, a right angle drill, variable speed, EZ outs and a
> > torch, (oxy/acetylene).  If you do have to completely drill out the
> > studs to the threads, you will need a heli-coil. High strength is
> needed
> > here. There is not enough material in the case for oversized studs or
> > solid inserts. As for how deep to drill, start with a small drill and
> > you will feel where the stud ends. Replacement hardware here must be
> at
> > least grade 10.9 including the washers. The wrong nuts are what
> probably
> > cuased the failure in the first place. Check the bracket carefully.
> > These are also prone to cracking.
> >
> > Dennis
> >
> > -----Original Message-----
> > From: Vanagon Mailing List [mailto:vanagon@gerry.vanagon.com] On
> Behalf
> > Of Paul Guzyk
> > Sent: Thursday, February 10, 2005 8:47 PM
> > To: vanagon@GERRY.VANAGON.COM
> > Subject: Broken bolts on 1.9L lower alternator bracket....
> >
> > On my 84 Vanagon the two studs that hold the lower alternator bracket
> > to the engine block have broken off (see Bentley page 27.15)
> >
> > ....and of course they've broken off behind the bracket aka inside
> > the engine block.  :(
> >
> > In order to get access to the holes in the block I removed the
> > alternator, the metal coolant cross pipe from water pump housing to
> > the passenger side head then I removed the oil filler tube from the
> > bottom of the block.  (The oil filler tube is held on by two 13mm
> > nuts, one easy to get at, one not so easy).
> >
> > Tomorrow I intend to drill out the two broken studs then re-tap them
> > with the standard 8mm threads.
> >
> > How far into the block can I drill?
> > If I go too far I assume I will break the water jacket?   That
> > wouldn't be fun...
> >
> > Anyone have a better solution?
> >
> > If you've rigged up some other way to hold the lower alt bracket
> > please post photos....
> >
> > -Paul
>
>