Blown sparkplug and insert

[kingsirspeedy]

So I had a sparkplug launch its self out the other day and found that it already had a threaded insert that came with it. I tried to screw it back in but it only spins. I know there are kits and things to fix a normal sparkplug whole but is there one for a blown insert as well, maybe an extra large option? if not do i need to get a new head?


the hole

its way bigger than the other sparkplug holes obviously

oh also when i way removing the engine the driverside nut was missing and had this weird circle thing on it. i ended up having to cut it off. not sure what or why it was put there.

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[Glenn]

[busman78]

Depending on the size of plug hole you have, Time-Sert makes what is called a Big Sert just for situations like yours.

[Ovally]

Captive nut engine case.
Close-up photo.

Regards.
_________________
VW Bug Oval 1953
VW Bug 1200 D motor
Porsche 911S MFI 1970
Mazda 929 Hardtop 1977
Mercedes SLC 180 Roadster 2018

[Cusser]

[consvws]

My dad stuffed a door handle (beehive type) spring over the spark plug, (small end over the plug) stuff the plug in there & thread the spring in until it pins itself under the engine tin.
I'm not recommending this, but I was amazed, the guy has been driving the bug for the last few years and drives by our shop all the time. The engine actually sounds good driving by & running on 4 cylinders.

Conrad

[Rickf1985]

You should be able to get the oversize insert for the plug and you may be lucky enough to find a junk case somewhere to get that nutsert from, if you did not destroy the hole in the process of beating it out. Otherwise you are going to have fun putting the bolt in and holding it while putting a nut on.

[goober]

[Cusser]

Look for a mechanic with TimeSerts and the tools for their install.

Or remove the cylinder head and have a machine shop repair it, or just buy a new cylinder head. This is not the end of the world.

I run a solid threaded insert on #2 in my 1835cc engine, has been fine for over a decade now.
_________________
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

[ashman40]

Just curious... if the spark plug hole is already too large for even the oversized TimeSert, is it possible to weld the spark plug hole closed/smaller and then tap new threads into the weld material to form a spark plug hole almost as good as new.
I'd imagine you would also need to form the flat seat that the spark plug washer/gasket seals against. Is there a specific cutter for this seat? I'd imagine such work would be done at a machine shop.

Would this welding and cutting a new spark plug hole cost more than what a new/rebuilt head would cost? I found new and rebuilt DP heads for around $250. This is probably a question for someone who works in a machine shop?
_________________
AshMan40
---------------------------
'67 Beetle #1 {project car that never made it to the road }
'75 Beetle 1200LS (RHD Japan model) {junked due to frame rot}
'67 Beetle #2 {2019 project car - Wish me luck!}

[kingsirspeedy]

[kingsirspeedy]

Do you think i should attempt to install a new captive nut or just use a normal nut and bolt. there is no dog house to get in the way in my case. I see I need to stop being so hasty with things, hind sight and all that.

[BMFBMF]

Post a picture of what's left on the case. You might also have to change your user name🤪

[Cusser]

[67rustavenger]

Or just replace the captive nut with a new one.
https://wolfgangint.com/case-components/2883-engine-case-nut-insert-111199102.html
_________________
I have learned over the years.
Cheap parts are gonna disappoint you.
Buy Once, Cry Once!

There's never enough time to do it right the first time. But there's always enough time to do it thrice.
GFY's Xevin and VW_Jimbo!

[ashman40]

[Pruneman99]

X2 for the captive nut. The double nut is an absolute pain by yourself. I have large hands, so I have an extremely hard time getting the doghouse tin off there with the engine in the car.

Something to think about if you go to a doghouse fan setup.

[Ovally]

https://wolfgangint.com/case-components/2883-engine-case-nut-insert-111199102.html

The correct VW number of the captive nut is 111101135 and not 111199102 as incorrectly stated in the link.

Regards.
_________________
VW Bug Oval 1953
VW Bug 1200 D motor
Porsche 911S MFI 1970
Mazda 929 Hardtop 1977
Mercedes SLC 180 Roadster 2018