[Vwdiesel] Injector boss cracks

[Val Christian]

Two thoughts:

a.) There are Al solders which can be applied with a propane torch.
It's not clear to me whether these could effectively be applied 
on a head, nor what their strength would be at 200F. But iff they 
were usable in such a situation, they offer a DIY opportunity.

b.) Battery operated impact tools are now offered by the major
power tool companies, including DeWalt.  The specs suggest that
these would work in the shop for most all applications.  They 
certainly offer a lower cost entry path for most newbies.  Furthermore,
they offer field usability, something my compressed air tools lack.
(I know a few people with 120VAC powered impact tools, but they're 
hard to find when you need a field repair on a car or a tractor,
and you out in the boonies.  And then there's the 120VAC power 
problem.)   

My experience is that everytime I think I can "just make the wrench 
work on this fastener" and avoid impact, I get burned.  It's amazing
but I break less with impact.

Val



> 
> Ditto what Loren said.
> Air or electric impact (air is better) has it's place in a shop for even
> supposedly delicate operations.  I have cracked ONE injector boss in my
> life, doing it by hand with a breaker bar, the correct way, so I was pulling
> the handle with my left hand, and pushing the wrench head with my right away
> from me.  I was in a hurry, and had the rolling cabinet with the hand tools
> there, and the air tools are all of twenty feet away on a shelf. Man was I
> pissed at myself.  Incidentally, just the top of the boss waws cracked, and
> I hand tightened the injector in and it took a torque alright, so it's still
> there for all I know.
> The thread is coarse enough that it could be welded easily, particularly
> with a spare injector inside as a heat soak/alignment jig.
> -James
> 
> -----Original Message-----
> From: vwdiesel-bounces at vwfans.com [mailto:vwdiesel-bounces at vwfans.com]On
> Behalf Of LBaird119 at aol.com
> Sent: Sunday, December 26, 2004 12:23 AM
> To: vwdiesel at vwfans.com
> Subject: Re: [Vwdiesel] Injector boss cracks
> 
> 
>   I had a cracked one and it was $25 to $35 or so to weld.  I doubt it'd be
> much
> more to weld 3 than 4.  No machining required/  :-)  I left him a core
> injector
> in case he needed it to hold thread dimension as the piece fell out.  It was
> cracked when I got the head.  Dad kept insisting I just grab a breaker bar
> and reef the injectors out of there.  I ignored him and continued gathering
> the proper socket, hose and the impact wrench and rattled it out.  He
> finally quieted down when I informed him of the damage it would have
> done had I used a breaker bar!
>   Impact wrench and penetrant is probably the best way to remove them.
> It doesn't tend to crack the head or break it unless it's already cracked.
>   A good welder shouldn't even flinch at fixing it from my experience.  :-)
>      Loren
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