Stripped exhaust studs

DK914 · 03-12-2001, 06:41 PM

The exhaust studs are pulling out of the heads on my '74 2.0, not an uncommon problem, I'm told, for 914s and early Vanagons. (Terrible feeling when you're torquing 'em down and the ratchet suddenly goes limp in your hand.) They've been repaired before, some with helicoils and others with "Timesert" threaded inserts. So basically it's a mess.
The heads are coming off soon. My question is, can the damaged holes for the studs be welded up (after the damaged inserts are removed) and re-tapped with reasonably long-lasting results? Does anybody have experience with this? And why did VW/Porsche come up with such a cheesy exhaust arrangement in the first place?!!!!
TIA for any help you guys can provide. I feel better already after venting.

John Rogers · 03-12-2001, 10:03 PM

I had the same thing happen on my daughter's car and had the heads pulled and holes welded and tapped for original sized threads. There is an oversize stud that can be used along with the inserts. Make sure when you or the shop reassembles the headers that there is enough thread on the stud for tightening so the nut doesn't bottom out on the threads before the gasket gets crushed, a washer can cure this. Good luck.

Conrad W Peden · Conrad W Peden's Garage

It can work just fine if you weld. But get a good welder. When I had mine done I found the "money is no object" professional welder to do it for me, and he did a good job.

I wanted it done right the first time guarenteed.

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CWP/VIR
72 914 L20E in rusto.
73 914 L20E 2.0L in resto.
http://members.rennlist.com/a914lover

SteveStromberg · 03-13-2001, 07:14 AM

Send them to: www.rimcovw.com

Steve www.914underground.com

JP Noonan · 03-13-2001, 10:31 PM

A little knowledge is a dangerous thing...

I orked in a NAPA machine shop and as far as I know (AFAIK) the only proper way to weld Al is to heat it o about 400 degrees before welding , otherwise the cracks will return.