Re: FW: 200q20v w. 3B & RS2 exhaust manifold

[quk@isham-research.demon.co.uk (Phil Payne)]

In message <01BE4E96.628CAD00.hah@srv.net> Henry Harper writes:

> 1.  first   to  drill a "hole" to  the  old  broken exhaust
> manifold studs
>      with special  drill concentration equipment
>
> "Bohrlehre  fuer Auspuffkruemmer Stiftschrauben  4+5  VAG"
> Partnumber  #G226/7
> Manufactured in Germany by
> W. Paschke
> Osterfeldstr.  29
> 3015 Wenningsen 4
> Germany
> Phone +49 - 5109 - 64224

This is just a device for centering a drill bit so that it goes down the
exact centre of a broken-off exhaust stud.  Almost any commercial jig
can be used.

> 2.  second,   after  drilling  you have  to turn  the
> broken stud back
>      with  this "Gewindausdrehsatz"  from  the aluminium
> head.
>
> Gewindausdrehsatz
> Part number:
> GR 1  M5 - M12  3/16"  --  1/2"
> Wa - Nr. 7.310,    9.2901      ????
> Nimeyer,  Remscheid,  Germany

These are normal stud extractors.  I think the idea is that the jig
is also used for these, to help prevent them snapping off in the stud.

> Gereedschappen  Equipment.
> Helmut Niemeyer GmbH.
>  Walter Freitagstrasse 9a
> 42899 Remscheid
> Deutschland
> +49 -  2191 - 95580

Yup, same outfit.

The big problem with this technique is what happens when it fails.
The stud extractors are _INCREDIBLY_ hard, and have to be removed,
if they break off, using either spark erosion or oversize drills.

Roger Galvin and I have adopted a policy of taking _ALL_ snapped off
studs straight to a local machine shop for removal - he charges GBP5
($8) plus GBP5 ($8) per stud.  Three broken studs is $30, and he's
done in half an hour.

--
 Phil Payne
 Phone: 0385 302803   Fax: 01536 723021
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