The front bolts are the problem. The studs in the rear were easy. I am
getting a helicoil kit tomorrow and am going to drill and fill the problem
bolts accordingly and replace them with stainless. Do you know of a place
nationally that I can get stainless M8 1.25 bolts for the replacement?
thanks, Cullen
----- Original Message -----
From: "Jim Akiba" <syncrolist@BOSTIG.COM>
To: <vanagon@GERRY.VANAGON.COM>
Sent: Tuesday, August 26, 2008 6:35 AM
Subject: Re: Header bolts broken

> Another great way for pulling steel studs out of Aluminum quick and
> easy is to TIG weld a bolt to the remaining portion and then twist it
> out. You get heat + you get a new head which are both really helpful
> at the same time. The only problem is you need to have a TIG welder
> AND be able to weld in funky positions which unless you have a finger
> amptroller is hilarious, knees, other people etc..
>
> Yeah sucks but definitely not the worst I think.  You're surrounded by
> lot's of folks with lot's of worse in vanagonland so the competition
> is pretty stiff ha.
>
> Do you have a drill that is low clearance enough for it as per Frank's
> suggestion?
>
> Jim Akiba
>
> On Tue, Aug 26, 2008 at 6:12 AM, Frank Condelli <RAlanen@aol.com> wrote:
>> 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
>>