Dl 50 problem
11-08-2009, 09:41 AM
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Dl 50 problem
Hey guys I have a slight problem with my Dl 50. My header came loose the other day while flying and I have noticed the threads are stipped out of the front exhauste hole. Have any of you had this problem and if so how did you fix it? I have been debating retapping for another bolt size. I may just end up calling jodi at VVRC to see if he has a fix or am I stuck getting another engine. Thanks for any help.
Rick
Rick
11-08-2009, 10:49 AM
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RE: Dl 50 problem
The easiest way to fix it is to use a helicoil insert, most automotive or general machine shops can do this for you at a fraction of the cost of a helicoil kit. The thread size is a 5x.08 mm, good luck.
11-08-2009, 10:55 AM
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RE: Dl 50 problem
The next time don't use a gasket. Headers have their own security issues due to lengths and moment arms. Combined with vibration from tuning issues or a lack of support they can wear oout a mounting boss very quickly if a screw loosens up or a gasket falls out from heating and cooling cycles.
Helicoils work great when you have enough remianing cast material to insert one. If you don't, it's time for a new head. You might also have the ability to drill and tap for a metric size one or two up form the m4 screw that had been there.
Helicoils work great when you have enough remianing cast material to insert one. If you don't, it's time for a new head. You might also have the ability to drill and tap for a metric size one or two up form the m4 screw that had been there.
11-08-2009, 11:10 AM
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RE: Dl 50 problem
Cyberwolf gave you the same advice I would have, and he got the bolt size right, sorry T.O.M. I can do it for you in the unlikely event you don't have a local shop that can. I would not drill and tap it for the next size larger fastener, you think you have muffler bolt problems now? Follow T.O.M.'s advice and ditch the gasket, thin film of Ultra Copper RTV and Locktite 262 on the bolt threads.
11-08-2009, 12:06 PM
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RE: Dl 50 problem
Thanks for all of the advice guys. I really apreciate it. When this happened I did not have a gasket on the header. I just ran around looking for a helicoil and aparently most people do not have a clue of what one is. Jody i may call you about this on monday. Thanks again to everyone.
11-08-2009, 02:35 PM
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RE: Dl 50 problem
Harder than hell to locate an m5 Helicoil. Sorry Jody, I flubbed the correct size originally. I've tried both methods and the Helicoil is the best for repair. I've also been forced to go with a new head due to a lack of workable material on some heads.
Supporting pipes and mufflers is frequently over looked and generally the cause of many attachment failures. One of the negatives of using flex headers as well. Unfortunately the threads at the exhaust ports are damaged when that happens.
Supporting pipes and mufflers is frequently over looked and generally the cause of many attachment failures. One of the negatives of using flex headers as well. Unfortunately the threads at the exhaust ports are damaged when that happens.
11-09-2009, 11:48 AM
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RE: Dl 50 problem
circman here is a site that carries the helicoil kit you need.http://www.nationaltoolwarehouse.com...qx/product.htm.
In the kit you will get several inserts of the size you need ,plus the tap and driver for the insert, I don't believe the drill is included,but I think it was a standard size found in a 29 piece drill set. Just another option or box up the cyl and send it in to Jody at Valley view ,he does this all the time and i am sure it will be a quality repair at a fair price.
Every bolt on the DL-50-55 is the same size so myself I would go for the kit just in case another one gets stripped out some where down the road. So now you have 3 options, all of which are way less than a new cyl or engine, good luck.
FYI going with the insert makes the repair quite alot stronger than the original, since the insert is stainless.
In the kit you will get several inserts of the size you need ,plus the tap and driver for the insert, I don't believe the drill is included,but I think it was a standard size found in a 29 piece drill set. Just another option or box up the cyl and send it in to Jody at Valley view ,he does this all the time and i am sure it will be a quality repair at a fair price.
Every bolt on the DL-50-55 is the same size so myself I would go for the kit just in case another one gets stripped out some where down the road. So now you have 3 options, all of which are way less than a new cyl or engine, good luck.
FYI going with the insert makes the repair quite alot stronger than the original, since the insert is stainless.
11-09-2009, 01:20 PM
#10
RE: Dl 50 problem
One more time coming loose and wiping out the threads would render the cylinder useless. There would not be enough material left to go the next size bigger or drill oversize and Heli-Coil again at 6mm. Heli-Coil it now at 5mm and if it ever comes loose again it won't do any more damage to the jug.
11-09-2009, 06:46 PM
#12
RE: Dl 50 problem
ORIGINAL: Bedbug
Redrilling it to me is the best way, you would have to tap it out so the heli coil would screw in so why not dill and tap a new hole?
If you have enouhg steel to work with good luck .
Redrilling it to me is the best way, you would have to tap it out so the heli coil would screw in so why not dill and tap a new hole?
If you have enouhg steel to work with good luck .
When I fixed mine, I simply drilled a little bit so that the 6mm tap can go through. There is enough material for the 6mm bolts to hold strong. I did not consider heli-coil as I was not sure there is enough material for the coil.
The header material is pretty soft. It was an easy job to drill and tap.
11-09-2009, 10:12 PM
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RE: Dl 50 problem
Cyberwolf thankyou very much for the info. I may just go ahead and order one anyway. I did find out sunday afternoon that one of my fellow club members works in a engine shop and said he could do it for me as long as he has the helicoil. If this does not pan out or I need work done to this that I am not comfortable doing I will definetly be calling you jody as you are the man when it comes to this stuff. I definetly know where I am buying my next engine from. Thanks again to everyone for their help.
Rich
Rich
