Well, it had to happen. I've killed the Stag

[SaskStag]

Hi all,
I'm about to open a large bottle of wine.........

One of the threads holding on the far bolt for TH's alternator bracket was always dodgy. Needless to say, before I could do anything, a couple of trips later and the one nearer bolt sheared off. So the alternator dropped; no damage there though.

So I figured this would be a good time to learn to Helicoil. It's a darned awkward place, but I did the far bolt. Then I had to drill out the sheared off bolt. Really awkward to do, but I managed to get the bore done using a right angled drill. The drill suddenly gave way, but I thought I had just broken through the last of the bolt end, as it was being pushed down by the drill then stopped and it was only about an inch in, not long enough for the bolt. Drilled some more, then suddenly I was at 2 and a half inches in. Anyway, did the tap and placed an insert. I started to break off the tang, but instead there was nothing and a sound of something falling inside the engine.


I'm done for the night.............. looks like my summer is over before it began. Looks like I'm going to have to strip that side of the engine down. This is now well beyond me. Or.....maybe, consulting the oracle, it's just the timing chain cover and a sprocket I've helicoiled??

Tanya

[Firept]

Tanya.
Oh No what have you done .....dont worry about it have some wine chill out and look at it tomorrow and really asses what has happened, take some photos if you can and post then so we can see what you are trying to do its bound to be " fixable" so dont despair.
We all probably know that sinking feeling when something like this happens. whilst trying to get the last piston out of the block I juggled with it and dropped it on to the plastic tray I had under it so it would cushion the blow ...but.... it hit the edge and broke the piston ring... a few choice Anglo Saxon words seemed appropriate at the time still all mended now and been back together now for some time.

It will look better in the morning.
All the best
Paul.

[Dieter H. Marschall]

Hi all,
I'm about to open a large bottle of wine.........

One of the threads holding on the far bolt for TH's alternator bracket was always dodgy. Needless to say, before I could do anything, a couple of trips later and the one nearer bolt sheared off. So the alternator dropped; no damage there though.

So I figured this would be a good time to learn to Helicoil. It's a darned awkward place, but I did the far bolt. Then I had to drill out the sheared off bolt. Really awkward to do, but I managed to get the bore done using a right angled drill. The drill suddenly gave way, but I thought I had just broken through the last of the bolt end, as it was being pushed down by the drill then stopped and it was only about an inch in, not long enough for the bolt. Drilled some more, then suddenly I was at 2 and a half inches in. Anyway, did the tap and placed an insert. I started to break off the tang, but instead there was nothing and a sound of something falling inside the engine.


I'm done for the night.............. looks like my summer is over before it began. Looks like I'm going to have to strip that side of the engine down. This is now well beyond me. Or.....maybe, consulting the oracle, it's just the timing chain cover and a sprocket I've helicoiled??

Tanya

Hello Tanya,

I feel sorry for you when I read about your bad luck. Hopefully the damage is not too bad and you are still able to enjoy your summer in the Stag.

By the way something similar happened to me last weekend: It was our second trip this year in our TR6. When I parked the car near a filling station an elderly gentleman cut the corner and bumped into the front of my TR. Bumper, lamp and wing have to be replaced.

Have a bottle of good wine.

Best wishes,
Dieter - from Germany.

[flying farmer]

OOPS!

I think you may have gone a little deep here, the casting is only about 1 1/2 inches thick so you probably have gone through to the timing sprocket.

Take off the cam cover that side and have a look inside, the odds are that the helicoil has fallen into the sump. Bearing in mind where you are, if you are lucky and the cam cover gasket comes off intact you might be able to re use it with a smear of gasket sealant.

You will probably have to drain the sump and see if you can swill the helicoil and any tapping swarf out of the drain hole.

To block the hole in the timing cover you may have to use two helicoils to fill the full depth, the first one may need to be shortened.

Make a plug by cutting off a short length of appropriately threaded bolt, cut a screwdriver slot in the end and screw it towards the end covered in thread locking compound.

Fit the second helicoil in to the remaining length of the hole to finish the job then reassemble.

The alternative is to just use a single helicoil and the original bolt covered in gasket cement, that should stop it leaking but if ever it is removed it will need resealing again.

Best of luck!

Neil

[Westfaling]

Bugger! would be the appropriate term down here.
As stated all may not be lost if the offending items reappear from the sump plug. Don't give up yet!
Nick

[KOY 23]

Hard luck Tanya, this sort of "disaster" has happened to most of us and to the professionals. Youv'e made repairs and modifications that most people and many on this forum wouldn't even contemplate. Drilling out a sheared off bolt is not an easy job but you've done it and retapped it, you were almost there.

Neil's advice is as always good. I think the difficult part will be getting the bits out, I hope you will be lucky there.

The only advice I can give is don't try to start the car, as the bits will spread, just warm up the sump with a heater to thin the oil. Also put a strainer (old pair of tights?) over the drain can to catch the bits.

Good luck.

John.

p.s. Lucky you aren't Russ's dentist or he would have rows of bolts on his head and chin.

[jleyton]

I'm joining in with my sympathy, but no constructive comments I'm afraid as pretty much everything useful has already been said.

If the forum could get grumpy2 through his engine disaster I'm sure it can get you sorted

Good luck.

Julian

[Giles]

As Julian has said the guys above have given all the advice but does not seem too bad. Good luck, it will soon be sorted.

[grumpy2]

Well tanya, if this lot can get me through my issues I'm sure they can help with yours. Sounds like sensible advice above to me but as I found sometimes the phrase "just take the......off" was the hard part! All worked out well in the end for me and I'm sure it will for you too


All the best

Gary

[Kevin Garrod]

. Also put a strainer (old pair of tights?) over the drain can to catch the bits.

D

Tanya doesn't sound like the kind of girl who wears tights!

[v8ken]

Hi Tanya,
Yes some great advice given,,I don't know wether you can get a small magnet in (one of those on the end of a telescopic rod)mine has saved me a few times from major dismantling,,also for future reference,I have never drilled before helicoiling aluminium and it's always been successful.(It actually was on the instructions on the box,when I did my spark plug hole)no drill needed for aluminium.
Good luck.
Regards Ken.

[milothedog]

Some pictures may give us a better idea of how to help you proceed but as well as all the suggestions above you may be lucky if you take the timing cover off and might be able to retrieve the bit's you don't need in there.

Ian.

[SaskStag]

Thanks for all the advice! I'll try the cam cover off first to check any damage to the sprocket. As luck would have it I had ordered a bunch of spare parts from LD, including a sprocket and silicon gaskets. And I have a spare cork gasket that was used for 1 day. It needs an oil change anyway.

It's all the work ahead of me that fears me most....and the damage I'll probably do on the way!!!

If necessary, is it easier to take off the oil sump rather than the timing cover???

I was so dismayed I forgot to use a few choice words, but my father thinks that all the Stag parts are called 'bugger' after watching me a few times!

I might have a pair of tights somewhere for those special occasions; like now!!

Cheers
Cup of coffee first and onwards...
Tanya

[milothedog]

Thanks for all the advice! I'll try the cam cover off first to check any damage to the sprocket. As luck would have it I had ordered a bunch of spare parts from LD, including a sprocket and silicon gaskets. And I have a spare cork gasket that was used for 1 day. It needs an oil change anyway.

It's all the work ahead of me that fears me most....and the damage I'll probably do on the way!!!

If necessary, is it easier to take off the oil sump rather than the timing cover???

I was so dismayed I forgot to use a few choice words, but my father thinks that all the Stag parts are called 'bugger' after watching me a few times!

I might have a pair of tights somewhere for those special occasions; like now!!

Cheers
Cup of coffee first and onwards...
Tanya

Much easier to do the timing cover, you have to drop the front cross member and support the engine to get the sump off.

Ian.

[SaskStag]

Timing cover then if it comes to that.
Tanya