Solenoid nipple repair
 

The precontrol/wastegate solenoid nipples are commonly broken off when attempting to remove previously baked-on hoses.

Despite how careful I thought I was, I managed to break one of mine.

Here is a quick overview of how I fixed it.

First, the ugly:
http://www.rotormafia.com/solenoidfi...ensolenoid.jpg

I started off by filing down the leftover piece of the broken nipple:
http://www.rotormafia.com/solenoidfix/2_filed.jpg

Here is the replacement nipple. I cut it off of an old Honda CRX intake manifold that I had in my garage.
http://www.rotormafia.com/solenoidfix/3_newnipple.jpg

Using my drill press and a 5/32" bit, I carefully drilled into the solenoid. The depth of the hole is about 1/8". Having the nipple sit inside the solenoid is important if you don't want it to easily snap off again.
http://www.rotormafia.com/solenoidfix/4_drilled.jpg

I had to lightly tap the nipple to get it seat all the way in. The hole is about .010" smaller than the nipple to ensure a nice interference fit.
http://www.rotormafia.com/solenoidfix/5_almostdone.jpg

The last step will be to put a little JB Weld around the edges to make doubly sure that the nipple will never fall out. I have to go get some JB Weld or I would be able to finish tonight. :p:

Sonny

Beyond sweet! Very very nice work. Makes me want to go do that to ALL my connections. Just to be sure, ya know?

Nice job Sonny. That looks pretty good. You are now an official member of the Cheap Bastard Club. I am the founder :)

For future reference, use an exacto knife to slice the old hose before removing it. That should reduce the number of broken nipples. Nipples should be treated gently, with extra care and finesse :D

Adam,

Are you talking about solenoid nipples or....? :rofl:

I got the whole rat's nest out last night. I broke the nipple on the Relief 1 (blue) solenoid, but I'll try to fix it. Heater gun and an exacto knife will be my friend.

Sonny

I like your repair job. New solenoids are expensive.

Done!

http://www.rotormafia.com/solenoidfix/6_fixed.jpg

I used the "fast dry" JB Weld (cures in 4 hours), so it's a little darker than their standard stuff.

Sonny

Are you going to flare the end a little to help keep it on?

I think I might goober a little jb weld around the end to make a flare. I don't want want to apply too much force to the nipple and break something else.

I could tig weld a small bead around the outside...think I could do it without melting any plastic? ;)

Sonny

I bought some small rubber o-rings and epoxied those to the tubing in order to create a "flare". They work perfectly.

Good idea, Damon! :beerchug:

Sonny

nice repair job. as for the flare didn't it break taking it off. a flare would seem to ensure chaos when taking it off if it gets a little baked on..