Broken Oil Cooler Mounts

[AndrewLeshovsky]

Hey All,

So last night we removed the fan housing on our '64 Beetle to discover the external oil cooler that was installed in our Beetle wasn't just for extra cooling. We had every intention of returning the engine to stock with a VW oil cooler, but discovered two very large bolts threaded into the engine case as well as both factory mounts broken in half. Needless to say, we were quite disappointed to find our little Edie in this condition (we've owned her for about two months). Does anyone know a fix for this? Aside from a new engine? We're planning to put the external oil cooler back on, but reluctantly.

We don't know it yet, but we fear the OEM muffler coming in the mail won't fit with the oil pump installed that brings oil outside the vehicle. Any suggestions to get this car stock?

Thanks, Andrew

PS What are the openings for the oil cooler supposed to look like? Our's are threaded into the case where the oil would flow in and out. Was that done to put in these enormous bolts? Or is there something stock that should thread in there? Thx again.

[Harleyelf]

Pictures would help. The holes for the oil should be clean counter-bores.

What is broken in half, exactly?

[Cusser]

I'm guessing that he means that the two "ears" that have the holes through are broken, but don't know what he means about enormous bolts.

We need good pictures !!!
We need good pictures !!!
We need good pictures !!!
We need good pictures !!!
We need good pictures !!!
We need good pictures !!!
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[johnnypan]

Sounds like they tapped and plugged the oil cooler ports with bolts...if they drilled the seal seats when doing the the case is junk..the broken ears might be worked with by grinding the case and fabbing a bracket but in either case your cooler is way too important to cobble...Id get a case.


since it runs ok with the external cooler you have the luxury of time to build an engine..

[AndrewLeshovsky]

Yes, exactly, everyone is right. The two "ears" that the oil cooler mounts to are broken, rendering them useless. Today we just put the external oil cooler back on and put everything back together. Sounds to me like the oil cooler ports were tapped for block off bolts (the enormous bolts in the top of the case). Yes, I was sort of afraid the seal seats were tapped, thus ruining the case.

We're considering how long we can run it this way. So far nothing seems to be leaking. We're obviously very disappointed we can't bring it back to stock with its original oil cooler. Now we get to wait to see if a stock muffler will work with the aftermarket oil pump. I hate when people screw things up...

Sounds like a new case is in Edie's future in the next 1-2 years.

[johnnypan]

[Harleyelf]

As long as it doesn't leak, drive it until it pops and then throw it away. Tune up parts, seals & gaskets, maybe some rings and clean heads, keep it clean....

It could be years before you need to install the backup motor which you have slowly built in your closet.

[AXAM]

I have a box of old fixes. I will take a picture and send it to you. It's a metal fixture the shape of a "T" that slips into the case and supports the oil cooler. I came across a box of these when I bought out a old shop years ago.
I will be back home in a few days and I will take a photo.
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[siemsje]

I'm new here, so don't know if reviving a 4 year post is a no-no...but here goes.

I have this same issue in that one of the mounting tabs for my oil cooler is broken. From what I've read online, the case is Magnesium alloy which makes a welding repair problematic.

What options do I have for dealing with this? Is tapping the holes and installing an external cooler the best option?

[Eric&Barb]

As posted above an external oil cooler is not a good option.

Would be nice if AXAM would post an image....
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[AlteWagen]

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[carcrazed]

[bluebus86]

Sweet little repair. maybe even an angle bracket held by the nearest case bolt could be used, but apparently it is not needed, a simple plate, brillant!


Bug On with a clever repair!
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[Eric&Barb]

Probably work better by adding in the broken off part after a little filing off the inner side (toward cooler).
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[AlteWagen]

The bracket is more than just a bar, it is shaped like a T and fits into the hole in the case below the mount ears. I havent seen one in 20 years or so but they did work.

AXAM should post pics if he still has any left.
_________________
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[siemsje]

Thanks much for that idea guys! I'll give it a try