Just 3 head bolts?

[almo]

All good stuff guys, thanks again for all the comments. Latest is they're trying to drill/tap it out (excuse the lack of correct terminology, I'm more of a desk jockey than a grease monkey!). The main dilemma has been wether or not to throw more money at the rising labour costs with no guarantee of success, or to cut losses and replace. We're going a bit further with the fix option so fingers crossed time again...

[CycloneMike]

Have you considered a specialist stud extraction service. They will have it out no probs without scrapping your block.
Such as
http://www.extractengineering.co.uk/" onclick="window.open(this.href);return false;
You might need to Google to find one local you you.

[what2do]

Almo, as of yet, I still don't think you've said where the van/engine is. where in Blighty are you?

[clift_d]

Almo, as of yet, I still don't think you've said where the van/engine is. where in Blighty are you?

I think the VW 'specialist' who broke the stud is based in Cardiff.

[almo]

Breaking news..... The bolt is out and the head is on! After a great deal of blood, sweat and drill bits they have finally done it. Just waiting reassembly and the bill for labour which hopefully will be less than the cost of a new engine! We'll see early next week if it all works, but hopefully we're over the worst....

[almo]

Yes I'm near Cardiff.
Thanks for all the suggestions and feedback, I would definitely ask garage to get a specialist in next time as they said they wouldn't do it again! To be fair to the garage they have been great and gone the extra mile as they didn't really want to attempt the repair because the labour costs soon mount up to the point wherein becomes a sensible option to invest in a new recon. Different I know if you are able to DIY or have a mate in the trade. These guys were the only place I could find around here that would even attempt it, so hats off to them (Welsh VW near Barry).

[clift_d]

Barry…!!!???

[Plasticman]

barreeeeeeeeeeee island
mm

[what2do]

Good result for you mister.


Why oh why, do people drill these things out when it's easier and quicker than using a mig to extract them? I may have to put together a vid at some point and then others on here with a mig can have a go. Not renowned for my IT and media skills though so it may be on the back burner for a while!!!

[itchyfeet]

Email it to me and i will do it, after all it was my engine you did

[almo]

So all's done and dusted and had it back yesterday. New MOT too and the rebuilt motor is running lovely. The whole experience has made me realise that a rare beast like this is not getting any younger and needs more love than I can give it. I will put some pictures up soon on a new thread to see what you guys reckon I should ask for it, or if anyone has a suitable t4/5/6 that we could part-ex it.

Thanks again for all the responses and suggestions. Cheers.

[almo]

Final footnote, see my new thread entitled "89 Syncro with LPG - What's It Worth" for pics, description and request for price advice.