Dan MacMillan writes:
>1. TWee to put the heat exchanger/muffler back into the exhaust ports as one u
>unit, and _boy_ was it hard ... we even had the engine upside down at one
>point ... the pipes just wouldn't line up. Anyway, we finally did get them
>in, but in the process of tightening them down, one bolt on each head stripped.
>I'm sure I didn't over-tighten them ... is the metal of type IV heads unusually
>soft? Any ideas what I should do now?
I'd take them to an automotive machine shop.  If they're anything like 2.0
heads, they're pretty pricey if you mess them up too bad yourself.  When this
happened to me, I bought some replacement studs (same size, I believe) from
VW and took them, the heads, and the manifold that bolts onto them to a machine
shop.  (Not a repair shop.  These guys are the ones repair shops send heads,
blocks, cranks, etc. TO.)  They didn't seem too phased by it.  I think they
ground off the broken one and re-drilled and tapped the hole.  The other
hole was stripped and they filled it in with aluminum (heliarc, I guess) and
re-drilled it.  By letting them use the manifold, they could make sure the
holes were drilled straight and the exhaust would bolt on.  It only cost about
$20 (if that) and it was worth it to me to let people who do this for a living
handle it.

Pat Walsh, '71 Westy, walshp@ippdsgi3.nawc-ad-indy.navy.mil