Drilled through case! Watercooled

[Georgebug]

Hi, my mate was helping me drill out a snappedexhaust bolt out if my case and has drilled though it. (Only one has been drilled through)

Can I do anything with it now to repair or is un repairable?

Thanks

[kevtherev]

Scrap.
Unless you know of an Aluminium welder with heat treatment facilities

Didn't see this in our club wiki then?
https://club8090.co.uk/wiki/Pe ... stud_depth" onclick="window.open(this.href);return false;

[Jawin89]

Seconded, you will need to source another one.

[Georgebug]

Thx lads, I've got a 2.1, is a 1.9 head case comparable or does it have to be a 2.1?

[kevtherev]

Same heads

[itchyfeet]

Somebody did that before and managed to seal it with something but It probably won't last forever.

VW drilled two studs right through and sealed them, no idea why.

https://club8090.co.uk/forum/viewtopic.p ... 0#p8141321" onclick="window.open(this.href);return false;
Loctite 542 hydraulic seal suggested here.


I'd drill and tap M10 then use a stepped stud from VWH, don't fully tap and so the thread is tight and use sealant, worth a shot.

[ghost123uk]

I agree with Itchy ^^^^

And there is Loctite high temperature thread sealant. It's expensive, but if it works, it's not expensive

[windy]

How about tapping out & fitting a tapered plug, that can then be drilled & tapped for the exhaust stud?
I have the necessary plugs & could lend you the tapered tap required.

[itchyfeet]

How about tapping out & fitting a tapered plug, that can then be drilled & tapped for the exhaust stud?
I have the necessary plugs & could lend you the tapered tap required.

are these tapered plugs water tight under pressure?

[windy]

are these tapered plugs water tight under pressure?

Yes, I have even repaired cracks in cylinder head combustion chambers with them, so a 15PSI water jacket is no problem.

[itchyfeet]

great
post up details please of plugs and taps and any links?

[NicBeeee]

Would it be possible to counter bore the inside to fit an m8 stainless dome head bolt, use a suitable washer to seal.

[windy]

great
post up details please of plugs and taps and any links?

They are Irontite plugs made by Kwik way. Only available from the US of A.

[itchyfeet]

can't see that working, you would have to cut the excess plug off flush after inserting it. ^^^^^

[windy]

I didn't realise that it wasn't possible to grind the excess plug off. Is there lack of access where the exhaust studs are positioned?