> Date:    Thu, 9 Sep 1999 00:39:54 -0700
> From:    Todd Last <Rubatoguy@MINDSPRING.COM>
> Subject: Oh No! Misthreaded exhaust bolt?!
>
> In the continuing adventure of changing the coolant in my '88 Westy,
> because I really like the look of the blue VW coolant, I was reattaching
> the splash guards over the heads ( the ones that cover the head drain
> bolts) and I am afraid that I have misstheaded the exhaust bolt for the
> cylinder that is above the oil filter. I managed to get the bolt about
> 1/2 way in before I noticed that it was not going in straight.
>
> Now what do I do? Have I just destroyed my new rebuilt head? (The one on
> the Westy, not mine)
>
> Thanks,
>
> Todd
> '88 Westy
>
>
> P.S. Let this be a lesson to never rush a job because it is getting dark
> and raining.

You'll almost certainly have to remove the rear exhaust pipe completely.
You'll probably want to get an 8 X 1.25 tap and carefully chase the threads.
I think you'll be able to resurrect the hole without further disassembly,
but the tap setup has to be just right - you have to be able to turn it
STRAIGHT into the hole. I use a tap driver the fits on a 3/8" drive socket
extension, so I can use a ratchet handle to turn the tap. A couple 1"
"wobble-drive" extensions help too. These are available at most good parts
stores. Wobble drive extensions are WAY better than the typical u-joint type
for most things, because they allow much better control over the movement of
the driven tool; they are no thicker than the extension itself so they fit
in tighter spaces; they don't tend to bind on themselves the way the u-joint
type do.

Anyway, get the hole fixed, then when you start reassembling the exhaust
pipe onto the head, try to get both nuts and both bolts properly started
before tightening anything. I have great sympathy for your position, believe
me. I remember the first few of these I did - I wished that I had the
engineer responsible for the benighted pipe layout there... I'll say it
again: The key is, DO WHATEVER YOU HAVE TO DO TO GET THE STUFF STARTED
STRAIGHT BEFORE TIGHTENING. Be creative!

Coby

Valley Wagonworks
"Intimately acquainted with VW Vans since 1959"

Volkswagen Bus, Vanagon, Westfalia and Eurovan
Repair and Service Specialists

1535 Sir Francis Drake Blvd., San Anselmo, CA 94933
Voice:(415) 457-5628
Fax: (415) 457-0967
http://wagonworks.com
mailto:contact@wagonworks.com