crooked helicoiled EM stud :-(

[R Mangas]

   Hassle.  This could work, but you'll have to look closely at the amount
of space you have.  Like Jim suggested, enlarge the EM hole, then use a set
of spherically faced 'equalizing washers' to compensate for misalignment at
the nut/EM interface.

Go here: www.mcmaster.com and search on 'equalizing washer'.

   Good luck!

Robert




>From: Jim Green <jeg1976 at yahoo.com>
>To: auditude at cox.net, quattro at audifans.com
>Subject: Re: crooked helicoiled EM stud :-(
>Date: Fri, 4 Apr 2003 08:39:57 -0800 (PST)
>
>
>--- auditude at cox.net wrote:
> > Putting EM studs into my MC-1 donor motor with blue
> > loctite, I discovered that one of my helicoiled
> > holes in the head is a little crooked.  Crap.
> >
> > It is an upper stud, cylinder 4, and it is angled
> > down just a bit and interferes with installation of
> > the EM.
> >
> > If I recall correctly, this is a hole that
> > previously had some kind hackjob crooked stud in it
> > from the PO, which broke and was a pita to get out.
> > I still have the crescent-shaped piece of stud
> > threads that was all that was left after I drilled
> > it out and finally got it to come free.
> >
> > My helicoil drilling and tapping must've tracked
> > that wrong hole path.  (I don't believe it was
> > straight and I drilled the new hole crooked,
> > resulting in that crescent, but typing that makes me
> > wonder.)
> >
> > I'm tempted to pull the head off the motor, which is
> > on a stand, and take it into a machine shop to see
> > if they can bail me out.
> >
> > However, there may be other options.  I suppose it
> > may not be impossible to use something like JB Weld
> > to fill in the hole after I remove the helicoil, and
> > redrill and tap that material for the new hole.
> > This time I will use a bolted-on manifold as a jig.
> >
> > I don't want to use JB Weld if that is a hack or if
> > it will pull out later.  I didn't have much luck
> > with it in the past when I tried to attach a piece
> > of 17mm hex inside a destroyed tranny plug I
> > couldn't get out, so I don't have the best
> > impression of it.  I know others have been
> > successful tho'.
> >
> > Should I just eat the cost of the headgasket and
> > machine shop work and have a professional take over?
> >  Or, should I try another method?  I'm open to
> > suggestions.
> >
> > I'm thinking if I put the crooked stud in and try to
> > bend it straight, it will just end up breaking.
> > They seem to problematic even when they are
> > straight.
>
>Damn I hate stuff like this!  I wouldn't even
>consilder the JBweld option, just not a permanent
>solution.  I'd suck it up and just have a machine shop
>repair the hole for you.  It really is the only
>permanent fix.  Hopefully you just have a standard HG
>on there, and not a metal one, although I have heard
>you can re-use them once, especially if on a new
>install like yours.
>
>One other option, if it's not to far off, I guess you
>could enlarge the hole on the EM enough to get it on.
>You still will probably battle loose nuts since it
>will not seat properly.  God knows they need all the
>help they can get.  I just had one work it's way loose
>on my car, what a PITA!
>
>HTH,
>
>=====
>Jim Green
>'89 90tq 034EFI, Haltech IG5
>http://www.geocities.com/jeg1976/car_home.html
>
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