Mount for oil cooler broken

[mattscook27]

Hi, i just purchased my first beetle. its a 1961 and the engine and all that stuff was out of car when I bought it along with some new parts. One of the new parts was an oil cooler kit, upon taking the doghouse cooler off i noticed the top bolt is missing (see photo, i also put photo of gasket). i thought i could account for this by using the gasket and seals to make a good seal. When i start the engine now oil spews out of it. anybody have any ideas for me to get a good seal, i really wanna drive it.

[Eric&Barb]

Should be a stud there. Center punch what is left. Drill thru the center of the stud with a 1/8" drill bit. Then move up a size or two in drill bit and re-drill. Each time you drill it try to get the hole more exactly centered in the stud. Once centered as much as possible and the threads of the stud are all that is left in the hole. Use a machinist scribe or some smaller nails to pull/work out the remaining stud threads.

If you mess up the threaded hole you can go up to 8mm x 1.00 threaded hole and either install a straight stud or a 8 to 6mm stepped stud.
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[mattscook27]

okay i was thinking something like that, how far should i drill in? i dont wanns mess anything inside up

[bluebus86]

actually the drill will follow the path of the pilot drill. if the pilot drill is centered well, so will be the larger drills that follow unless you drill at an off angle. the key is to make the center punch dead center so the pilot drill starts dead center.


you probably do not want to drill thru to avoid getting chips inside the motor.

an easy out or simular excrator can be used once the hole is made.


if this is a job you dont want to do, a machine shop should be able to do this job for you.

good luck
_________________
Help Prevent VW Engine Fires, see this link.....Engine safety wire information

Stop introducing dirt into your oil when adjusting valves ... https://www.thesamba.com/vw/forum/viewtopic.php?t=683022

[txoval]

Those are the wrong seals too. Show a pic of the bottom of the oil cooler.

The paper gasket is not needed

Those black cylinder seals are for early engines with "original" early style coolers

Green ones are for early engines with "after market" early style coolers

Then there are red and white ones...it all depends on your engine and cooler

[mattscook27]

okay this may sound stupid but what is a center punch? there is a slight dent there which makes me think somebody may have tried this in the past.

Also here is the link to the oil kit adapter. in the instructions it said to use the gasket instead of the seals, but i just used both. then i tried only using gasket and it was worse. how could i find the right seals?


https://derale.com/products/filtration/engine2013-...kit-detail

[bluebus86]

[Q-Dog]

What is wrong with the stock oil cooler? Why do you think you need an external oil cooler?
_________________
Brian

'69 Dune Buggy
'69 Beetle Convertible
'70 Beetle

[mattscook27]

i dont think there is anything wrong with it, i just have an external one with a filter and would rather use that if i can

[Cusser]

Taking in to a machine shop is a great idea, this should be straightforward job for them, maybe while you wait. If they can't get the broken part out, the can drill and re-tap to 6 x 1.0mm.

If mine, I'd centerpunch and use my left-hand drill bits to drill out, oftentimes these catch and extract the broken-off part. If it didn't extract, I'd just drill and then tap to 6 x 1.0mm.
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1970 VW (owned since 1972) and 1971 VW Convertible (owned since 1976), second owner of each. The '71 now has the 1835 engine, swapped from the '70. Second owner of each. 1988 Mazda B2200 truck, 1998 Frontier, 2014 Yukon, 2004 Frontier King Cab. All manual transmission except for the Yukon. http://www.thesamba.com/vw/forum/album_page.php?pic_id=335294 http://www.thesamba.com/vw/forum/album_page.php?pic_id=335297

[mattscook27]

the old cooler is pretty crusty and a rusty color on the outside but inside looks to be good. i just bought these seals,

http://www.jbugs.com/product/111198029OR.html

ill try the original cooler to see if that leaks

[bluebus86]

do you really have the dog house fan set up? that was used srock on later bugs circa near about 1970 or so onward. it is a different fan fan house, cooler and such. if you got the stock system for your year bug it is NOT a dog house system.

note that if you do run a filter off the cooler, only a small part of the oil will be filtered, as not all oil passes thru the cooler there are other ways to install a filter that truely make the filter a full flow device.

so please check if you have a true dog house cooling system or not. if your bug has been upgraded to a dog house type of system, then you probably have no need for an external cooler on a stock motor.



dog house link....

http://www.vw-resource.com/oil_cooler.html
_________________
Help Prevent VW Engine Fires, see this link.....Engine safety wire information

Stop introducing dirt into your oil when adjusting valves ... https://www.thesamba.com/vw/forum/viewtopic.php?t=683022

[Q-Dog]

Without that top stud anything you put there will leak. Fix that first.
_________________
Brian

'69 Dune Buggy
'69 Beetle Convertible
'70 Beetle

[mattscook27]

Oh that is my mistake, I was under the impression that any oil cooler that stuck out of the engine was called a doghouse cooler. Mine is not a doghouse cooler and as far as I know is the stock from 1961.

Also is the stud threaded into the block or welded/attached in some other way?

[bluebus86]

[Eric&Barb]

Try a search of the WWW for "Center Punch". Youtube has lots of good videos on how to drill metal.

As for trying an Easy Out to pull out the stud remains, not a good idea. Easy Out should only be used when a stud or bolt is broken off, and the remains of the fastener is not stuck. Almost certainly that stud has corroded in place, thusly why it broke off.

Using an EO to remove a stuck fastener is a good way to break off the EO. Then you have to come up with a way to grind out the tip of the EO that is too hard to drill out. Dealt with such situations in the
USAF all too often and spent many an hour fixing such that had been done by others.
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[bluebus86]

[rockerarm]

My friend. WELCOME. If you lack the skills and/or the confidence I would suggest looking for some outside help. I used to live in North County. There is a vintage Porsche shop in Fallbrook and maybe he can help you or direct you towards a different shop. Escondido has a boat load of qualified shops or machine shops. If one knows the depth of that broken stud this is an easy game. Paradise in San Marcos is a full-on repair and machine shop. There is also a buggy shop north in Temecula.
If you continue on buying junk from jbugs I'm sure we will see your car in the classifieds or craiglist.
Hope this helps, Bill

[Eric&Barb]

[bluebus86]