Wayne,

I already proposed to my workshop to buy spare parts from PelicanParts. They are much cheaper than the current supplier , which is Porsche Italy with a miserable discount. There turnaround is about 3000 Euro/month for Porsche engines.

For the moment he is a little bit reluctant, first for the language problem, and second, he has already settled and does not really bother changing things. There is no time for burocracy and the owner prefers wroking with his own hands on the engines.

Andreas

Andreas,
Is Italy relatively cool by any chance?
I believe that here in (cool) New England, headstuds pulling is not as common as the literature would make you think. I think it is a question of temperature and perception. At one point, half the Porsches in the US sold were sold in (warm) California. Couple this with the fact that most of people writing about pulled head studs are probably in (warm) California and many Porsche machine shops fixing these head studs are in California and you get a perception of lots of pulled head studs.
I'm not against proper case preparation I'm just making an observation.
-Chris

On a mag case, installing case savers without doing any othe work is a waste of time. The case needs line honing/boring first. This sets a point where he case can be machined from. Then the case savers can be installed, the savers will stress the cylinder spigot hole so that will require machining and the deck height of the case will require machining too. The the long 8mm stud hole neds to be inserted. This is the minimum.

Thanks for all the replies. But one thing to consider is this, sometimes people do not have an extra three to seven thousand to tear the entire motor apart for a daily driver. Especially when everyone around them is telling them how worthless the 2.7 is to rebuild on. My situation is simple, I don't have the money to do it right and I would rather save up for a aluminum case and do it right with that better foundation in the future whenmoney affords.

Until then I need to repair two pulled studs so I can drive to work for the next year, oil leaks and all. I am sure I am not the only guy who could use a quick fix, so I figured out a way to do it myself.

Here's what you do.
1. You pull off the cylinder and take off the piston.
2. Build a jig of 4 tubes slightly shorter than the head studs. The tubes should be square and side braced.
3. One of the tubes is short near the case to allow for the drill bit and tap.
4. You pull out the stud where you have a pulled one. Put on the tool drill out the case and tap it. The tool if made properly will hold the drill and tap perfectly square.
5. Put in the case saver and move on to the next one.

The tool should cost less than twenty bucks to make if you can weld.

Yeah is sucks to do a job like this and this way but sometimes it is the only option.

I did find a local to sell me the case savers.
They come from a place called Winzer USA.

Agreed, sometimes what you need is not what you want. But remember, you've only repaired two studs, the rest of the lowers are probably on the way out too. If you drive carefully and don't thrash the car it should be ok until rebuild time.

thanks, all the studs already have case savers in, but somehow two did not stick. I have also added a oil cooler to keep temps down.

I would be willing to bet that what pulled out was a Time-sert not a CaseSaver.
TimeSerts have finer threads than CaseSavers so they don't hold as well.

Will TimeSerts work ? Sometimes
Are CaseSavers better ? All the time.

It's the thread pitch not the insert diameter that is important.

Please don't get me wrong, for some jobs Time-serts are great, we use them for many jobs, just not head studs on MAG cases.

PS: We have CaseSavers and will be happy to sell them.

Do not despair.
I can build any engine I want and I chose to rebuild a 2.7 for my own car. A 76 912E Money is almost always an issue. http://forums.pelicanparts.com/uploa...1087669761.jpg http://forums.pelicanparts.com/uploa...1087669780.jpg

Cool Henry, I'll give you a call

Time Cert on the left.

CaseSaver on the right.

You choose

http://forums.pelicanparts.com/uploa...1088021025.jpg http://forums.pelicanparts.com/uploa...1088021047.jpg

what is the external thread size and pitch of the case saver?

not that I doubt that it holds up better that a time sert, I'm just curious about how thin the spigot gets around the insert.

TimeCert 11.5 x 1.5
I'm not certain but they may have a BigCert . They do in the 8mm size.

The CaseSaver pictured is 13.8 x 2.0
This CaseSaver is for a case that was already butchered with TimeCerts.
CaseSavers come in many different sizes.

thanks thats very helpfull

I just happen to know that. The 10mm Big-Serts are 14mm by 1.5. I wouldn't use one for a head stud, but they're good for a twice pulled engine to transmission mounting stud.

JP

Found: A place that sells Case Savers
 

I cam across this when I was looking for stepped studs.
This place sells case savers http://forums.pelicanparts.com/VWHelp.com
Type in "savers" in the search field to get a link to Savers and Inserts page.
-Chris