Oh man, that is hilarious. Sounds like he took off a bit of aluminum to make
it work. I'd love to see pictures.

Well, here's my inexperienced .02 on the head gasket change. I just did my
first one on my 88 GL w/ the engine out, had an instructor, took our time,
it went smoothly, plus allowed me to address anything else that needed
attention. Can't imagine doing it any other way. I also just received my 87
Westy last weekend on a flat bed, w/ the drivers side head removed.
Personally, I couldn't imagine doing that job w/ the engine in the van after
seeing it off in my westy. Maybe I'll change my mind once I do it a dozen
times (lets hope not). Plus, the engines in our vans are not that  hard to
remove.

Chris

On 9/7/07, Jake de Villiers <crescentbeachguitar@gmail.com> wrote:
>
> Here's Roger's final post in the series from January 2005.
>
> Did the repair as best I can,and went for a test frive of 15 miles today.
> Well, I can say I didnt destroy my 1.9.At <http://1.9.at/> times I thought
> I
> had. It started up and ran just fine this morning.
>
> I completely removed the right head gasket and replaced it with RTV/Quick
> steel.Costs $25. 6 tubes of quick steel and a tube of RTV.I have to watch
> especially during a cold spell at night.No leaks at all so far,here.
>
> The left bank however seems to have a small drip till the engine gets
> warm(only 1 heat up trial to go by) . This side was only patched with RTV
> /quick steel.Seems to be ok ,though.
>
> The problem is a pushrod tube was punctured somehow. these alujinum foil
> devices are fragile. I will cleanit off and pull outthe JB again for
> this.Thekey here is ruoghening up the aluminum and cleaning it
> first.Ivedone it before and no big deal
> here.I have a couple of adjustable tubes in reserve.
>
> The engine is very smooth. I think I found a oil leak in the breather
> tower. Loose nutz at the base masqueraded as a main seal leaking. I hose
> clamped every hose connection for insurance from vacuum leaks. The intake
> runner was loose at the base at the fuelinjectors. new o-rings at the
> injectors.Thanks forthe  tip on cutting holes inthe tin to remove the head
> draining bolts,Mike.
>
> Yeah, lots of work and not what you want others to see.I passed the point
> of no return when I removed lots of aluminum from the head and case where
> they meet. I want roughened surface area and immaculate cleanleness for
> the
> RTV and QS.If this is successful in the long run, I think Iavoided other
> pitfalls of cylinder head removal.namely stud snappage and costs.Engineruns
> smoooooth.I never considered a rebuild for this or any WBX,so the heads
> were
> fair game to whatever need ed to be done.Head removel is not doable at
> this
> point, but that never mattered to me.Just not going there with a  engine
> with 187K.
> If this works till summer, I may do the other bank like the one I just
> did.Imagine freedom form head gasket leaks and phosphate free
> antifreeze.Love the lack of power.
>
> I used an old drill bit and let it rip.u know when hylou are trying to
> drill  a hole and the drill skips allovwer the place? I cleaned the insid
> ea
> nd outside of the head and case to perfection.Gouge city.
>
> Verylow tech stuff. No special skills needed except loonacy.No special VW
> tools except contemmpt for head gasket technologyand money all tied up
> elsewhere.
>
> On 9/7/07, Nunya Business <bulletheadx@gmail.com> wrote:
> >
> > Oy. Never mind- he just posted this afternoon. I tell ya these meds mess
> > with yer head, man.
> >
> > Cya,
> > Robert
> >
> >
> > On 9/7/07, Nunya Business <bulletheadx@gmail.com> wrote:
> > >
> > > Was it straight JB? I was thinking it was some sort of 'stuffer' with
> JB
> > > over it. I wonder how it held up to vibration...?
> > >
> > > Wonder where RS has been, he's usually going for those frequent poster
> > > miles...?
> > >
> > > Cya,
> > > Robert
> > >
> > >
> > >  On 9/7/07, Jake de Villiers <crescentbeachguitar@gmail.com> wrote:
> > > >
> > > > I remember that.  Roger pried out the old dead gasket, sanded things
> a
> > > > bit and re-filled the gap with JB Weld.   Audacious to be sure.  :)
> > > >
> > > > Maybe time for Rog to update us on this unorthodox procedure.
> > > >
> > > > Mr Sisler?
> > > >
> > > > On 9/7/07, Nunya Business < bulletheadx@gmail.com > wrote:
> > > > >
> > > > > As I said 'IIRC'- I believe he dug out the gasket and crammed
> > > > > something else
> > > > > in there while the heads were still on the engine. I don't recall
> > his
> > > > > posting anything about it for a while now but at the time he said
> > > > > whatever
> > > > > he did was holding. I don't remember what he used or how he did
> it,
> > I
> > > > > just
> > > > > remember feeling a kind of morbid awe about the whole thing. : )
> > > > >
> > > > > Cya,
> > > > > Robert
> > > > >
> > > > >
> > > > > On 9/7/07, T.M. <tinkerman007@yahoo.com> wrote:
> > > > > >
> > > > > > On Thu, 6 Sep 2007 11:58:20 -0700, Nunya Business <
> > > > > bulletheadx@GMAIL.COM>
> > > > > > wrote:
> > > > > >
> > > > > > >IIRC Roger Sisler has BTDT. You might want to talk to him about
> > it.
> > > > >
> > > > > >
> > > > > > Hi Robert. What do you mean by BTDT? Go through the whole head
> > > > > gasket
> > > > > > replace scenario or just re-seal them externaly like I'm trying
> to
> > > > > see if
> > > > > > possible?
> > > > > >
> > > > > > Cheers,
> > > > > > TM
> > > > > >
> > > > >
> > > >
> > > >
> > > >
> > > > --
> > > > Jake
> > > > 1984 Vanagon GL
> > > > 1986 Westy Weekender "Dixie"
> > > > www.crescentbeachguitar.com
> > > >
> > >
> > >
> >
>
>
>
> --
> Jake
> 1984 Vanagon GL
> 1986 Westy Weekender "Dixie"
> www.crescentbeachguitar.com
>

--
Chris
88 Vanagon GL (daily driver)
87 Westfalia (in progress)