Hello! Log in or Register   |  Help  |  Donate  |  Buy Shirts See all banner ads | Advertise on TheSamba.com  
TheSamba.com
 
My take on the alternator bracket broken stud issue...
Forum Index -> Vanagon Share: Facebook Twitter
Reply to topic
Print View
Quick sort: Show newest posts on top | Show oldest posts on top View previous topic :: View next topic  
Author Message
lonbordin
Samba Member


Joined: June 11, 2006
Posts: 29
Location: Bloomington, Indiana, USA
lonbordin is offline 

PostPosted: Sun Jan 13, 2013 6:37 pm    Post subject: My take on the alternator bracket broken stud issue... Reply with quote

Sooo... My engine bit the dust in a cloud of blue smoke. (I was so hoping it'd make it through the winter!) I need to have a second vehicle so I bought a second-hand working engine. The bracket looked weird but it ran and it wasn't expensive so I pulled the trigger.

Upon inspection the studs were missing and the "fix" made more damage. Thanks P.O., sigh... I know... don't talk bad about P.O. as we'll all be one someday.

Image may have been reduced in size. Click image to view fullscreen.


I tried the weld on and remove method three times in the right stud only to have a small piece of the stud come out each time. I just need this motor to make it to late May so I stepped back and looked for a work-around. I wanted the fix to be light on tools and easy.

Image may have been reduced in size. Click image to view fullscreen.


I used 1/4 flat bar. Heated it and bent it into shape with a bench vise and a hammer and drilled out the holes... easy does it and what a great use for a power steering mount (as I don't have power steering). This fix could be done just about anywhere.

Image may have been reduced in size. Click image to view fullscreen.


Just trying to give back to a group that's given me so much. Thank you!
Back to top
View user's profile Send private message Classifieds Feedback
Jake de Villiers
Samba Member


Joined: October 24, 2007
Posts: 5911
Location: Tsawwassen, BC
Jake de Villiers is offline 

PostPosted: Sun Jan 13, 2013 6:55 pm    Post subject: Reply with quote

Full marks for resourcefulness and open-mindedness - that's a good solution as long as you're not using the power steering pump mount.
_________________
'84 Vanagon GL 1.9 WBX
'86 Westy Weekender Poptop/2.5 Subaru/5 Speed Posi/Audi Front Brakes/16 x 7 Mercedes Wheels - answers to 'Dixie'
@jakedevilliersmusic1
http://sites.google.com/site/subyjake/mydixiedarlin%27
www.crescentbeachguitar.com
www.thebassspa.com
Back to top
View user's profile Send private message Send e-mail Visit poster's website Instagram Gallery Classifieds Feedback
rubbachicken
Samba Member


Joined: October 05, 2004
Posts: 3058
Location: socal
rubbachicken is offline 

PostPosted: Sun Jan 13, 2013 7:13 pm    Post subject: Reply with quote

i have drilled out those studs and re used the holes, so far 2 for 2 Smile
_________________
lucy our westy

lucy's BIG adventure

meet 'burni'


markswagen {mobile mechanic} san diego area all early VW's cared for.

619 201 0310 or 617 935 4182
Back to top
View user's profile Send private message Send e-mail Facebook Gallery Classifieds Feedback
lonbordin
Samba Member


Joined: June 11, 2006
Posts: 29
Location: Bloomington, Indiana, USA
lonbordin is offline 

PostPosted: Sun Jan 13, 2013 7:21 pm    Post subject: drillin' tappin' Reply with quote

The P.O.'s attempt at a fix removed a significant amount of metal around those stud inserts, see first picture. I was less comfortable about drilling out further AND that (to me) was a longer path full of potential peril.

I don't have power steering BUT I did have the power steering bracket from a previous donor.

I'm in NO WAY claiming this is the way to go with this issue BUT I though it was worth offering up as an alternative. Smile
Back to top
View user's profile Send private message Classifieds Feedback
dhaavers
Samba Member


Joined: March 19, 2010
Posts: 7717
Location: NE MN (tinyurl.com/dhaaverslocation)
dhaavers is offline 

PostPosted: Sun Jan 13, 2013 7:25 pm    Post subject: Reply with quote

Ingenious! Nice workaround!

[whisper]
<Just don't let TK find out...>
[/whisper]
_________________
86 White Westy Weekender
"The WonderVan"

<EDITED TO PROTECT INNOCENT PIXELS>
Back to top
View user's profile Send private message Gallery Classifieds Feedback
Vinzanto
Samba Member


Joined: March 22, 2012
Posts: 247
Location: Kansas City
Vinzanto is offline 

PostPosted: Sun Jan 13, 2013 7:39 pm    Post subject: Reply with quote

I had the left stud break off on my Westy and was unsure how to approach it. Luckily at the same time, I was helping a friend do a head gasket on his vanagon and he had the same issue but only on the right stud.
We attempted to extract the broken stud and failed. We then tried to tap it out to a larger size but discovered THE HOLE ALREADY HAD A HELICOIL INSTALLED..uuugh; he ended up creating a bracket that did mount into a PS mount hole (its okay his westy was not equipped with ps).
So after our bout with a broken stud I took my van into a local semi-trustworthy shop, and it took them over two weeks to extract the bolt. I had to pay 6 hours of shop labor @ $65 and ended up paying over $400 for an extracted stud.
Alll in all I hope the new bracket holds up for you!
Back to top
View user's profile Send private message Gallery Classifieds Feedback
Hatterasker
Samba Member


Joined: October 31, 2011
Posts: 207
Location: Pacific Northwest
Hatterasker is offline 

PostPosted: Sun Jan 13, 2013 9:15 pm    Post subject: Reply with quote

I just removed my alternator. Some previous mechanic broke off the left stud in the hole.
Back to top
View user's profile Send private message Gallery Classifieds Feedback
Hatterasker
Samba Member


Joined: October 31, 2011
Posts: 207
Location: Pacific Northwest
Hatterasker is offline 

PostPosted: Sun Jan 13, 2013 9:19 pm    Post subject: Reply with quote

rubbachicken wrote:
i have drilled out those studs and re used the holes, so far 2 for 2 Smile


He Rubbachicken,
How'd you do it?
Thanks,
Matt
Back to top
View user's profile Send private message Gallery Classifieds Feedback
Vanagon Nut
Samba Member


Joined: February 08, 2008
Posts: 10333
Location: Sunshine Coast B.C.
Vanagon Nut is offline 

PostPosted: Sun Jan 13, 2013 9:35 pm    Post subject: Reply with quote

Way to make it work!

Several years ago, back when I started my engine swap, I too did a "temporary" fix to a 1.9 with worn alternator mount and snapped bolt

https://sites.google.com/site/musomuso/alt.tempbrackets

I also added a second bracket between a tab on an exhaust flange and bottom of twisted bracket. https://sites.google.com/site/musomuso/bracketpage2 In hindsight, maybe not a great idea? (vibrations cause exhaust flange to crack?)

After dumping all the gas/oil out of the engine Shocked and borrowing a pair of injectors from Jake, got it running and found that the alternator was pretty stable and lined up "ok".

Neil.
_________________
1981 Westy, 15º ABA

1988 West, 50º ABA

Vanagon VAG GAS engine swap Google Group:
https://tinyurl.com/2f24rmh

VE7TBN
Back to top
View user's profile Send private message Gallery Classifieds Feedback
Display posts from previous:   
Reply to topic    Forum Index -> Vanagon All times are Mountain Standard Time/Pacific Daylight Savings Time
Page 1 of 1

 
Jump to:  
You cannot post new topics in this forum
You cannot reply to topics in this forum
You cannot edit your posts in this forum
You cannot delete your posts in this forum
You cannot vote in polls in this forum

About | Help! | Advertise | Donate | Premium Membership | Privacy/Terms of Use | Contact Us | Site Map
Copyright © 1996-2023, Everett Barnes. All Rights Reserved.
Not affiliated with or sponsored by Volkswagen of America | Forum powered by phpBB
Links to eBay or other vendor sites may be affiliate links where the site receives compensation.