DJ2.1 Rebuild

[maxstu]

Trying to find it locally is a task and a half. Two or three day wait buying online, too.
I really wanted to run in engine this week. Oil changed after 150 miles. Then 500 mile return journey to T3MEET.
Getting close

[maxstu]

Would an old-fashioned thing like a core plug work, p'raps? It must be said that I'm in  no way an expert - just thinking out loud....!

Ian P.

I would prefer to seal up hole and then use Loctite 577

[Ian P.]

Hope the Loctite fix works, Stu! Loctite of various grades and applications is used extensively in the aerospace industry, so I'm sure, with the correct type / grade, you'll be fine. Best of luck, and looking forward to a positive update!!

[maxstu]

Cheers, Ian P.

[mrhutch]

next day delivery on prime https://amzn.eu/d/0ypmnIH

[mrhutch]

Eurocarparts Canterbury has one in stock, Thanet can have one by tomorrow morning

[mrhutch]

I wouldn't be sealingthe hole though, that jbweld breaks off and plugs a water gallery at some point and you've another headache

[maxstu]

Eurocarparts Canterbury has one in stock, Thanet can have one by tomorrow morning

Strange. This morning I went into ECP in Thanet and asked. They said not stocked anymore

Kent Bearing in Tankerton will have it in stock from their Ashford branch by 11am tomorrow.
Same price as Amazon, too.....who l refused to use, anyway.

[maxstu]

I wouldn't be sealingthe hole though, that jbweld breaks off and plugs a water gallery at some point and you've another headache

I wish l could see down the hole with some lighting!

Trouble is the hole depth is 31mm deep with a 3mm hole into the waterway. But stud only goes in 26mm before locking. No internal thread thereafter, perhaps. So there will be a void filling with coolant behind the stud.

I would prefer to reduce that potential threat by getting some JB weld in there. But not necessary pushed through the hole. Just up against it.

How much pressure is there in the coolant system to break it away?

[mrhutch]

it's obviously +ve pressure, but I doubt it's very high unlike an oil gallery

Good news on Kent bearings

[maxstu]

Thanks.

[Stesaw]

Wouldnt you be able to tap the hole further in stu, enough to stick some threadlocker on a short threaded bar then put the stud on top of that as per normal?

[mrhutch]

Wouldnt you be able to tap the hole further in stu, enough to stick some threadlocker on a short threaded bar then put the stud on top of that as per normal?

What would be the point??  You're not going to be removing that exhaust stud for the foreseeable

[maxstu]

Thanks to both.
Another set of measurements.
Depth of hole 31mm.
Thread stops at 16mm and not 26mm. My typo.
Mr Hutch, lm not sure this will be classed as a permanent repair. So the void for coolant is larger than first realised; and I am furious with myself for not checking stud depths before fitting both heads. Still, it didnt leak coolant with the head stud in place. I actually left the coolant slightly pressurised overnight, too.

I now have seen breakthrough down the stud hole. It's not a circular hole. More of a moon waxing crescent shape on its side. So the breakthrough is far larger than first thought.

[maxstu]

I did consider cutting additional thread to approx 28mm. Then adding a kind of grub stud cut from an old steel exhaust stud. Cut a slot across it's head and use a flat blade screwdriver to wind it down with a dab of JB Weld attached to it face. Then add the exhaust stud.

I dunno at the moment. I've lost a bit of faith in my own abilities today. Probably need to rest up and rethink again in the morning.

I think l may as well consider a replacement head in the near future.

Thanks to all. Signing off for today.