In a message dated 25/08/2008 10:12:35 P.M. Central Standard Time,
LISTSERV@GERRY.VANAGON.COM writes:

        Well, that's sort of NORMAL  !  I have them break off frequently no
matter how careful I am.  So,  now you will have to get out the drill and drill
bits and start drilling them  out and insert Helicoils.  You will need to
source 35mm long Helicoils or  stack the common short ones.  The ones at the
front are not that hard to  attack with a small air drill but the ones at the back
- WHOA !!!!   I  have a very small right angled air drill and a whole series
of cut off drill  bits to do them !  Time consuming for sure but can be done
with the engine  in the van.  The other option is to remove the heads but then
your into a  complete reseal job !   NO FUN !  Get the surface good and flat
before hitting the broken off bolt with a centre punch and try to get it as
centred as possible.  Start with a 1/8" drill bit and be careful not to  break
it off !  Then go up in size maybe 2 or 3 sizes so that you can rock  the bit
back and forth to get the hole centred if it was not at the  beginning.
Eventually you will get to the proper size bit that will allow  you to run a tap in
there for the Helicoil.  Be careful to not drill past  the original depth or
you WILL go into the coolant chamber and then the head is  scrap metal !  Use
only carbide drill bits !!  Keep the drill bit in  the bolt and DON'T let it
wander off into the aluminium (NOT EASY) especially at  the rear !

>>>>>The worst has happened. After very patiently  removing the nuts and
bolts =
on my wbx I twisted 2 off and still have 1 to  go. They are flush with =
the head and have nothing to grab onto. What are  my options with out =
removing the head. They are obviously not grade 5 or  8, but good old =
garbage grade 2 considering they twisted off with a  minimum amount off =
force. Is it possible to helicoil these while in the  van?<<<<<<<<<

Cheers,

Frank  Condelli
Almonte, Ontario, Canada
'87 Westy & Lionel Trains (_Collection for sale_
(http://members.aol.com/Fkc43/trainsal.htm) )
_Frank Condelli &  Associates_ (http://members.aol.com/Fkc43/busindex.html)
- Vanagon/Vanagon Westfalia Service in the Ottawa Valley
_Vanagon Stainless Steel Exhaust  Systems_
(http://members.aol.com/Fkc43/exhaust.htm)
_BusFusion_ (http://members.aol.com/BusFusion/bfhome.htm)  a VW Camper
camping event, Almonte, ON, June 12 ~ 15,  2008