>I have "stripped" the threads on one head.  Is there any good alternative
>to dismantling enough to get a drill in position to drill out the damaged
>threads, cut/tap new oversized threads, and insert a heli-coil?
>

I believe VW also makes a special stud which is oversized on one end only
so the head can just be tapped out to a larger size.

I have often found it difficult to install the exhaust pipes without having
some mismatch in the holes that leads to stipping the threads out. The
secret I discovered is to disconnect the other end of the left and right
exhaust pipes from the fitting where the two pipes come together. This
gives you another degree of freedom to line up the exhaust pipes on the
head and get the bolts/studs in without stress. Connecting the other ends
of the exhaust pipe back to the fitting can then be a challenge, but if you
can safely use a little more persuasion on that end without damaging anything.

*****  John Clavin  |  jjc@bga.com  |  Austin, TX  ***************************