Club 80-90 Forums

ah yes sorry
025919086
M16x1.5

https://www.vwheritage.com/025919086-oi ... r-vw-spare" onclick="window.open(this.href);return false;

Cheers Paul.
I've been hunting for that, couldn't find it anywhere.
M16 drilled out to clear the presumably stripped thread would be a big hole to get an adapter or insert for.
An M16x1.5 timesert needs a 16.7mm drill and a M17.8 tap.
The inserts are cheap but the tooling is expensive.
Unfortunately, 3/8 NPT is just too small.

What I do have is a 3/4 x 20tpi UNEF tap set and 11/16" drill, that's 17.4mm.
Now I just need a 3/4 x 20 adapter. I havn't got a die to make one.

Hmm, not looking easy is it. You can get the full helicoil kit, including separate drill bit, for ~£65 on ebay as an option, helicoil will probably be OK, if not preferred. I think the biggest I have is M14. Is there a machine shop near you, might be cheaper just getting it done ?

Here's a link to the page with the oil pressure switch etc https://volkswagen.7zap.com/en/rdw/typ+ ... 19-136005/ It's in the electrical section.

Cheers for the link to the fishe. item 4 is the adapter but I would need to repair the thread first.
I'm not convinced a helicoil would do.
Another option would be an M18x1.5 banjo+ bolt (with tap and 16.5mm drill) to hose to remote sender.

We (at work) are the closest thing to a machine shop within at least 100 miles. we have a couple of lathes and a selection of random taps/dies/drills/helicoil kits that might help.

Sounds like you've got a few engineers to get views from.

Helicoil wouldn't be my first choice, but think about the helicoils that were holding the studs for the barrels in place. Far more force there, for the oil pressure switch your objective is for it not to leak, with probably max 5-6 bar oil pressure when cold, compared to 11 bar on the heads (accepted more than one fixing) when not firing, much more when running.

I'd say driling and fitting a helicoil is the least of your problems
keeping the dirt and swarf from the oil ways will be the hardest part
you might even find the thread is there under the jbweld

Helicoils are perfectly good enough for this job.

Dirt and swarf can be sucked through the oil filter hole with a hoover.
Helicoil would certainly be strong enough but I was worried about leakage, however there's a sealing ring (dowty seal?) under the adapter that does the sealing so I was worried about nothing.
Another option would be to drill and tap the hole to 3/4 UNF and fit one of these-



Which I can cap off until I fit the remote sender.

bigbadbob76 wrote:Dirt and swarf can be sucked through the oil filter hole with a hoover.

.

or blown out with an airline

bigbadbob76 wrote: Helicoil would certainly be strong enough but I was worried about leakage, however there's a sealing ring (dowty seal?) under the adapter that does the sealing so I was worried about nothing.
.

It isn't a dowty seal, just a simple aluminium crush washer by the looks of things, they tend to leak from the seal on the pressure switch anyway - mine did

https://www.vwheritage.com/n0138444-o-r ... l-vw-spare

The build is on!!!!!

bigbadbob76 wrote:Dirt and swarf can be sucked through the oil filter hole with a hoover.
Helicoil would certainly be strong enough but I was worried about leakage, however there's a sealing ring (dowty seal?) under the adapter that does the sealing so I was worried about nothing.
Another option would be to drill and tap the hole to 3/4 UNF and fit one of these-



Which I can cap off until I fit the remote sender.

doubt that will fit there is very little space

Standard copper washer on mine

937carrera wrote:
It isn't a dowty seal, just a simple aluminium crush washer by the looks of things, they tend to leak from the seal on the pressure switch anyway - mine did

https://www.vwheritage.com/n0138444-o-r ... l-vw-spare

That's what I expected it would be, similar to a sump plug, but not what they are according to VWH. Not an easy part to find either.

937carrera wrote:. You can get the full helicoil kit, including separate drill bit, for ~£65 on ebay .

you don't need a kit look for a tap a blacksmiths drill and buy some helicoils got to.be cheaper

I burned the midnight oil last night.



The pressure switch hole is staying as it is until i find a good solution.

Have you used up all those shiny new parts already

Looks like an early start this morning too, you'll be taking a nap at work, not too far away now