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  #81  
Old December 17th, 2012, 10:33 AM
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Neill Thornton
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Well RDS just cryptically said "they are out of stock until next year". Waiting to hear back from RovahFarm, and Will Tillery doesn't seem to have a website...

So I guess I am looking at a UK purchase.
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  #82  
Old December 17th, 2012, 10:47 AM
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A UK purchase for what? a glow plug? I have some old ones laying around if you need one

Dont Helicoil the head, it will just rattle out. I would us ea Time-Sert they are 1000000000x better and come in every damn size on the planet
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  #83  
Old December 17th, 2012, 11:01 AM
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mark kellgren
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I think he's sourcing a new head.
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  #84  
Old December 17th, 2012, 11:05 AM
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Neill Thornton
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Quote:
Originally Posted by Naplm00 View Post
A UK purchase for what? a glow plug? I have some old ones laying around if you need one

Dont Helicoil the head, it will just rattle out. I would us ea Time-Sert they are 1000000000x better and come in every damn size on the planet
I am looking at getting a new head...

What makes the Time-Serts different from helicoils?
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  #85  
Old December 17th, 2012, 11:08 AM
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Ah crap, dont have that on the shelf!


Also: http://sykes-pickavant.com/Products/...n/Default.aspx


I think the glow plugs in a 200TDi are the M8x1.00 thread

http://www.amazon.com/TIME-SERT-Metr...s=M8+time+sert

This would work to fix the head.

------ Follow up post added December 17th, 2012 11:10 AM ------

Quote:
Originally Posted by navydevildoc View Post
I am looking at getting a new head...

What makes the Time-Serts different from helicoils?


A time sert is a sold pices of steel alloy that LOCKS into the metal. You will dril the hole larger then tap it to a newer larger internal thread. then inset the timesert with bearing mount of red hi temp locktite on it. It then gets "swagged" into the hole with a hammer and punch included in the kit.

We used them in the USAF all the time to repair engines, even aircraft engines





I can check to make sure of the threadpitch on the plugs i have at home
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  #86  
Old December 17th, 2012, 11:25 AM
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OK did some more research.. Glow plug thread is without a doubt M8x1.00 I dont know the overall length of the threaded portion, but if i rememebr correclty it isnt very long. I think you could get away with trying to use the timesert kit...esp if the head is off the engine

Could save you some serious coin
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  #87  
Old December 17th, 2012, 11:48 AM
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Quote:
Originally Posted by Naplm00 View Post
OK did some more research.. Glow plug thread is without a doubt M8x1.00 I dont know the overall length of the threaded portion, but if i rememebr correclty it isnt very long. I think you could get away with trying to use the timesert kit...esp if the head is off the engine

Could save you some serious coin
Those look like they would hold for sure. this forum is so great for new ideas.
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  #88  
Old December 17th, 2012, 12:51 PM
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But the glow plug have a tapered seal, don't they? Over drilling for the insert will destroy the seal.
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  #89  
Old December 17th, 2012, 01:02 PM
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Quote:
Originally Posted by Red90 View Post
But the glow plug have a tapered seal, don't they? Over drilling for the insert will destroy the seal.


Crap, didnt think of that... Im not sure where it seals or seats. If the seat is tapered at the bottom, overdrilling would totally bone it


Looking at a bucnh of pics I cant really tell where the sealing surface is...might be at the bottom of the threads..bummer
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  #90  
Old December 17th, 2012, 01:04 PM
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Neill Thornton
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Quote:
Originally Posted by Red90 View Post
But the glow plug have a tapered seal, don't they? Over drilling for the insert will destroy the seal.
Quote:
Originally Posted by Naplm00 View Post
Crap, didnt think of that... Im not sure where it seals or seats. If the seat is tapered at the bottom, overdrilling would totally bone it
Yup. You can't drill and tap them without being uber careful.... even then the threads don't go for a long distance in the bore so I am not sure this is fixable.
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  #91  
Old December 17th, 2012, 01:45 PM
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Quote:
Originally Posted by navydevildoc View Post
Yup. You can't drill and tap them without being uber careful.... even then the threads don't go for a long distance in the bore so I am not sure this is fixable.

what a bummer...another option to save the head would be to get it welded and tapped, but that could warp it. Or you could just pipe tap it and put in a pipe plug. Just skip the heater in that cyl

I would still prob try if it is already fucked
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  #92  
Old December 17th, 2012, 02:14 PM
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If you have the cash and the time, do both. Order a new head and try to fix this one. Best case scenario you'll have a spare head.
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  #93  
Old December 17th, 2012, 02:20 PM
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Well, a new "performance head" which is ported by Turner Engineering is just over 600 bucks, which I have a feeling doesn't cover shipping. A standard head is only slightly cheaper, so I might as well get the fancy one.

The only place in CONUS that has the head even for sale is Rovers North, and they want $1,300 for it and it's backordered.

So I guess this whole shebang is on hold until I can donate plasma, sperm, kidney, or liver for cylinder head money.
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  #94  
Old December 17th, 2012, 02:59 PM
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There's a bunch available on ebay.co.uk for under 250 GBP. I say your immediate fix is to pull the head off and do the thread approach. that sounds pretty straightforward.

You might also check with a machine shop locally. they can probably repair the thread. they may have to weld in aluminum then retap, or they can put the insert in for you. they probably do this all the time, and for a fraction of the cost.
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  #95  
Old December 17th, 2012, 03:07 PM
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Quote:
Originally Posted by Overlander View Post
There's a bunch available on ebay.co.uk for under 250 GBP. I say your immediate fix is to pull the head off and do the thread approach. that sounds pretty straightforward.

You might also check with a machine shop locally. they can probably repair the thread. they may have to weld in aluminum then retap, or they can put the insert in for you. they probably do this all the time, and for a fraction of the cost.
For some reason I didn't even think about going to a machine shop. Huh.

I need to ask around and see if there is one local that's recommended. There has to be with all the crazy off-road/sand rail work done around here.
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  #96  
Old December 17th, 2012, 05:23 PM
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Quote:
Originally Posted by Naplm00 View Post
Crap, didnt think of that... Im not sure where it seals or seats. If the seat is tapered at the bottom, overdrilling would totally bone it


Looking at a bucnh of pics I cant really tell where the sealing surface is...might be at the bottom of the threads..bummer
The seal is the small tapered bit at the bottom of the thick shaft above the heater portion.
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  #97  
Old January 7th, 2013, 09:33 PM
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Neill Thornton
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Well, just an update... After talking to a machinist from a well regarded cylinder head shop here in town, I decided to get a new head.


So..... I have a new Turner Engineering "performance" head on it's way from the UK.
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  #98  
Old January 8th, 2013, 01:17 PM
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Quote:
Originally Posted by navydevildoc View Post
Well, just an update... After talking to a machinist from a well regarded cylinder head shop here in town, I decided to get a new head.
What was his view on the machining as a matter of interest?
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  #99  
Old January 8th, 2013, 01:59 PM
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I'm gonna guess that since the head had already been skimmed it was too far out of spec to have the glow plug thread fixed and then to have the head machined flat again.
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  #100  
Old January 8th, 2013, 03:31 PM
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Neill Thornton
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A bunch of things all together... One was the history of the overheating, the fact it was skimmed once on the Alaska trip, and the doubt in how well a helicoil would hold under the high compression of a Tdi. A timesert won't work for this particular hole due to the need to drill in the little lip. All in all, the guy said he would helicoil it, but said I should never have anyone standing near the bonnet when it's running in case it decided to give way and turn the glow plug into a mini missile.

Turner Engineering claims a 15 HP boost with their "performance" head, so I guess we will see how that goes. I placed the order online this weekend and already received a notice from DHL that it cleared customs and could be delivered as soon as this afternoon. Amazing.

So I guess I should get on the horn to Rovers North and order a new gasket.
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