Club 80-90 Forums

Any advice would be appreciated. Purchase a t25 couple weeks ago seem all good but it started backfiring and was getting worse, after some investigation i noticed where the exhaust on the left meets the head the bolts were wrong and there was some weld on one of the bolts
Then realised that it's not really connected.
The one bolt that had weld on it had come free. It was just pushed in not holding anything.
The other one seems OK but a dodgy size.
Has anyone had a problem like this before and if so how did you deal with it?!

Hi and welcome.
I guess we are talking a petrol wbx or Aircooled?
best get a photo up of the offending area and we can see how bad it looks.
Post a photo bucket link is easiest.

Ok
Reads like the PO had a stud snap and replaced it with a bigger one, not wanting to do any more he welded it on the other side.
This mess is yours now and will have to be put right.
Remove the exhaust and any studs you can with a stud extractor.
That's easier said than done imho.
The larger studs/bolt diameter is not a problem

This job is much easier with the engine dropped or out on a bench.

Hi guys thanks for the replies.
I will get some photos the area.
I've managed to get one of the bolts out, but im still struggling with the other one, think it might be best if I cut it off. Then i can try and deal with getting the bolt from the head. I have been told I can get it helicoil fitted once I have them out.
Hoping to get the exhaust system off today
I'll keep you posted on how it's going again thanks everyone

I have just done this on an Aircooled engine, the studs had been loose for some time and threads were gone in head.
Engine out , head drilled, tapped and oversize studs from VW Heritage fitted.
Pretty simple on Aircooled but don't fancy the extra hassle of wbx.
Good luck,
George

Well after a couple of crazy days I've managed to sort.
So lucky, I welded a nut on the end of the bolt, with the dodgy head and got it out so both out wohoo!!!!! Really pleased. Just now got to see what I can do about the other side I found the nut on the top looked good but the one underneath had rusted completely away. Not sure what's holding it to the head but it is holding at the moment. Gonna go for a much deserved drive tomorrow
And enjoy
Thanks I'll keep you posted on progress

You've been fortunate so far, enjoy it.

Take care if you have to drill the stud hole for a Helicoil, there is not much "meat" between the bottom of the (blind) hole and the water jacket. Itchyfeet has a picture of it cut away to show this.

Itchyfeet has a picture of EVERYTHING