Club 80-90 Forums

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

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;

Seconded, you will need to source another one.

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

Same heads

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.

I agree with Itchy ^^^^

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

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.

windy wrote: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?

itchyfeet wrote: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.

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

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

itchyfeet wrote: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.

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

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?