In a message dated 21/07/2005 12:09:08 AM Eastern Daylight Time,
LISTSERV@GERRY.VANAGON.COM writes:

Any  rate, I've been told that to replace the helicoil
with the next size up is  the way to go.  I'm nervous
about doing this because:

A) Never  installed a heli-coil before
B) I'm concerned bout drilling the case by  hand and
having to keep a hand drill square to the case so I
don't get a  cock-eyed hole
C) Concerned about drilling too deep!
D) How do I keep  the drill chips from getting into the
engine and slowly machining my newish  powerplant
apart?

I'm looking for some real-life experience from  those
out there who have gone this route.  I'd like to know
how  people solved the issues I listed above and how
long the fix worked for  them.

I'f you've used another solution to this problem, that
worked,  please let me know about that too.  (No, I'm
not going to use an old  spark plug.)

Barry, I would try using a No. 5334-14 , M14x1.25  "Sav-A-Thread Spark Plug
Port Repair Kit" to solve your problem.  This kit  is made by HeliCoil a Black
& Decker Company.  It comes with a two  stage tap that will allow you to make
the proper threads in the casing, without  the worry of drilling off centre,
to insert the new threaded insert.   This is a much better solution that using
an ordinary HeliCoil as it will  withstand many removals and insertions of the
drain plug without failing.   The chips of metal will either fall out due to
gravity working in your  favour or stick to the tap because of the oil on it.
Either way  there's no problem with chips being left behind to destroy your
motor.

Cheers,

Frank  Condelli
Almonte, Ontario, Canada
'87 Westy, '90 Carat & Lionel  Trains
Vanagon/Vanagon Westfalia Service in the Ottawa Valley
_Frank Condelli &  Associates_ (http://members.aol.com/Fkc43/busindex.html)
or http://frankcondelli.com
_STEBRO/Vanagon Stainless Steel  Mufflers_
(http://members.aol.com/Fkc43/stebro.htm)
_BusFusion_ (http://members.aol.com/BusFusion/bfhome.htm)  a VW Camper
camping event, Almonte, ON, June 09 ~ 12,  2005