The head can most likely be welded (weldment will completely replace the
broken off ear) and re-tapped for about $50.  You will have to remove
it, and take it to a welding shop that can handle aluminum alloy
welding.  I have done this many times with cases, works great.

Forget the JB Weld, it can't take that much heat.

Jay & Kim Schmidt wrote:
>
> All knowing list:
> What would you do with this scenareo? 84 westy exhaust replacement lead to
> an engine drop, drilling, tapping, cussing, etc and I installed a few
> stepped studs(oversize). On reassembly, the 8th and final stud broke the pot
> metal  "ear" where the stud goes into the head and appears ruined. Many
> options here:
> 1)buy a new head if replacing just one is kosher,
> 2)replace both heads with new/rebuilt,
> 3)ship the whole engine for a rebuild as it is torn down anyway and overall
> condition unknown(but it ran well)
> 4)JB weld the hell out of the broken portion and retap to get on down the
> road quickly and inexpensively.
> 5)cut my loss and get out now and think twice before buying a decent running
> westy needing exhaust work next time.
> I'm leaning toward 1,2,or 4 as this isnt a bus I want to replace EVERYTHING
> on as i have with my 77. The condition just doesn't warrant it. I don't want
> to sink more into this than it will be worth. If I rebuild the eng and the
> auto trans goes 2K later, I just can't eat the loss. I can't be roped into
> continued heavy bills just to prevent taking a loss either. At this point I
> have MUCH time, but little money in this westy. The body will never be
> great, maybe average with work. Would it be a mistake to start pouring major
> $ into it?   If so, #1 or 4 is the way to go right?
> Some of you have  probably been here. I need your hindsight. I think my
> long-speculated theory that one would be WAY ahead by spending a small
> fortune on a mint or already restored vdub(as opposed to a "deal" on a
> project) is panning out. Your advice is appreciated. Moral support gladly
> accepted also.
> Jay, 77 westy
> Kim-still driving a Buick oceanliner:(

--
Stuart MacMillan
Manager, Case Program
800-909-8244 ext 208

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