Started sounding like a slipping belt about a month ago. I had a look, and sure enough No.1 stud was snapped, and the cross docking stock was all sooty.
Contemplated doing it myself, but the potential for turning the head into a paperweight whilst trying to remove the snapped stud was too great.
So, ordered a gasket and studs from the club shop, and booked the Bongo into a local trusted engineering workshop. The sort of place who can re-grind cranks, skim heads (and manifolds) etc.
Dropped it off last night, and was a bit worried when I called this afternoon and it wasn't ready. I had left them a copy of the factsheet. I mentioned it, and advised that whilst I wasn't trying to teach them to suck eggs it might be worth a look through. They agreed. I also laboured the point that the water system was not to be broken into, and that the turbo can be split to avoid this. They agreed this too.
When I called them, they said that the job was taking a while, and that it was awkward since the drivers seat didn't lift very far (full side conversion). I suggested that they could just un-bolt the seat from the lid..... I guess they were at the EGR pipe union at the back of the head. Don't know why they didn't remove the rear cover, as advised in the factsheet...
Anyhow, I just went down to collect it, and all's well. No leaks, no dramas, no "oh, we dropped the coolant, but it'll be OK now we've refilled it" or any other such worries. A bill for 4.5 hours labour, £40 for a skim and VAT. £258 all in. More than I expected, but a lot cheaper it could have been in the worst case.
Once the manifold was off, they got it on the flat table, and it was rocking around. It was twisted along the length. Around 5mm proud at the front with the back on the level. In the words of the man "It took 'a good skim' to get that one flat".
So, I'm a happy bunny again (Poorer, but happy)
). Replacement was sourced from a reputable 2nd hand parts dealer that arrived (after 9 days 
) even more bannana like than my shot one 
Luckily time wasn't an issue as new head, rings & exhaust were ongoing at the time.
i know what you mean with the paperweight comment, 
.i took 2 days looking at it all stripped down ready and waiting before i plucked up the courage to plug the drill in 
