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Thing exhaust studs
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Hot Rod Harp
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PostPosted: Fri Feb 16, 2018 12:18 pm    Post subject: Thing exhaust studs Reply with quote

Hey everybody, have a question regarding 1600 exhaust studs.
I broke one on the rear removing a rusted out merged header according to the
microfiche it calls out for 8X35 stud. I see vendors offering 8X40 and 8X50 studs.

Which one should I use?

I still have heater boxes and was going to install a Tri Mil thru the bumper.
I suspect the extra length is to accommodate the thicker flanges.

I searched for the correct length, but did not find an answer.
Hoping to drill out and replace with out dropping engine.
Also what's the deal with 12mm exhaust copper nuts for the 8mm studs,
better or just gives more room to wrench?

http://www.busdepot.com/059129601

Thanks in advance for the input.

Harp
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74 Thing 1600DP
76 Westfalia 2.0L FI
69 Beetle 1500SP sold
88 Goldwing GL1500/6 sold
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Glenn Premium Member
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PostPosted: Fri Feb 16, 2018 12:35 pm    Post subject: Re: Thing exhaust studs Reply with quote

M8x35 is correct. If you can't get a 35mm the 40 will do.
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Glenn
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Hot Rod Harp
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PostPosted: Fri Feb 16, 2018 1:28 pm    Post subject: Re: Thing exhaust studs Reply with quote

Thanks Glenn, can't locate M8X35....I'll order M8X40.
Any opinion on the copper nuts?
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Glenn Premium Member
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PostPosted: Fri Feb 16, 2018 1:47 pm    Post subject: Re: Thing exhaust studs Reply with quote

Hot Rod Harp wrote:
Any opinion on the copper nuts?

Most are just copper coated.
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74 Beetle Specs | 74 Beetle Restoration | 2180cc Engine
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Hot Rod Harp
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PostPosted: Sat Mar 10, 2018 10:22 am    Post subject: Re: Thing exhaust studs Reply with quote

To follow up with this thread, the M8X35 studs are indeed available. I ordered the M8X40 it should help with the thicker Tri Mil flanges. Regarding the copper 12mm exhaust nuts, they are smaller than stock 13mm should give extra room also they are lock style where the outside end is deformed to lock around the stud, most likely good for one time.

On with the show, contacted one local air cooled shop ($85.00/hr) regarding replacing studs. Response was maybe 1-2hr /stud.....stop

I see replacement heads from $160 to $276 each.
(Cip1, BusDepot, JBugs, MoFoCo)

Burned out one of my drills attempting drilling out stud after welding nut on did not work (several times). So waiting for more equipment and the weather to break (2 Nor'easters in one week).

I'll continue drilling stud out without using an easyout, just retap. Then try another one, if this does not work out, I'll drop the engine when it warms up and pull the heads. Money of course is an issue so what would be wisest, just replace and repair originals later, or machine shop now. Note engine seemed to run well before.
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Hot Rod Harp
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PostPosted: Sat Mar 31, 2018 4:39 pm    Post subject: Re: Thing exhaust studs Reply with quote

Warmed up some and was able to drill out the broken stud and tap M8X1.5.

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Next will be to hang the Tri Mil and see if it leaks or not.
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76 Westfalia 2.0L FI
69 Beetle 1500SP sold
88 Goldwing GL1500/6 sold
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Hot Rod Harp
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PostPosted: Thu Apr 12, 2018 2:39 pm    Post subject: Re: Thing exhaust studs Reply with quote

I repaired holes in the heat exchanger and tried to test fit, problem with other lower stud I'll have to replace it also.
Should I use Ultra Copper Permatex or paper gaskets?

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Still patching wheel wells.
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74 Thing 1600DP
76 Westfalia 2.0L FI
69 Beetle 1500SP sold
88 Goldwing GL1500/6 sold
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Hot Rod Harp
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Joined: March 02, 2008
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Location: Englewood, New Jersey
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PostPosted: Tue Apr 17, 2018 11:30 am    Post subject: Re: Thing exhaust studs Reply with quote

Was told to use the aluminum gaskets that came with the exhaust system,
but they are aluminum center with some type of materiel on each side that I damaged.

Ordered compression gaskets from CB Performance, ok for new studs but too thick for worn studs.

Bus depot has Sabo brand aluminum sandwich gaskets for $0.95 each
111251261B

BTW the copper 12mm nuts won't fit due to built in flange/washer makes it larger than 13mm and hits the Tri Mil flange weld.

Bottom line I got the exhaust on after breaking a couple of drill bits in attempts to re-tap.
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74 Thing 1600DP
76 Westfalia 2.0L FI
69 Beetle 1500SP sold
88 Goldwing GL1500/6 sold
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