Big hole in aluminium oil drain plug
Discussion
Imagine this hex shape replaced by a ragged hole, with the rest of the aluminium plug still stuck fast in the sump.
Now imagine at least two of those ‘fins’ are missing due to a screwdriver and hammer being used on them.
Seeing as I’ve gone this far, how can I make it worse?
And if it can’t get worse, what can I do to get the fker out?
Now imagine at least two of those ‘fins’ are missing due to a screwdriver and hammer being used on them.
Seeing as I’ve gone this far, how can I make it worse?
And if it can’t get worse, what can I do to get the fker out?
Olivergt said:
After the heat, you could try a stud extractor tool? You might have to drill out the hole a bit to get it nice and round.
Yep, I've even been thinking about what shapes would give the best friction/grip - including a large slot to take a thick bit of flat bar bent at 90 deg to act as a long lever/handle.ReverendCounter said:
Tango13 said:
Is there enough room to get a drill in there? ]
Yes but the problem is, the thread diameter is about 30mmTime for plan 'B' which involves a brave pill and a carbide rotary burr, drill out as big as you can then use the carbide burr to open up the hole until the core of the thread is just showing. Then you can try ttting it with a hammer and cold chisel to try and break the remaining thread to get it undone.
Bee very careful though as the carbide burr won't be taking any prisoners and they can go through steel at a frightening rate never mind an ally crankcase!
Plan A, drill 2 holes either side and make up a bar with to 'pins' in it (like the sort of thing you'd undo a grinder disk with), put pins in holes and use bar to undo the plug.
Plan B, drill 2 holes either side and tap them; put to holes in a bar and bolt the bar to the plug then undo.
Plan B, drill 2 holes either side and tap them; put to holes in a bar and bolt the bar to the plug then undo.
Jazzy Jag said:
What bike is it?
Looks like a Yamaha?
Use a Punch or small chisel on the outer part but be careful not to damage the engine casing.
Yes, Yamaha 125Looks like a Yamaha?
Use a Punch or small chisel on the outer part but be careful not to damage the engine casing.
Tango13 said:
Time for plan 'B' .. brave pill…carbide rotary burr, drill out as big as you can … open up the hole … try ttting it with a hammer and cold chisel …
Given I can be a cack handed baboon at times, I might relegate this to plan Z due to an increase in desire to commit arson when things like your suggestion don’t go as planned.But I do understand the approach, despite access being a bit difficult
tvrolet said:
Plan A, drill 2 holes either side and make up a bar with to 'pins' in it (like the sort of thing you'd undo a grinder disk with), put pins in holes and use bar to undo the plug.
Plan B, drill 2 holes either side and tap them; put to holes in a bar and bolt the bar to the plug then undo.
This is similar to my thoughts of a flat bar bent at 90deg at the end, going into a slot cut into the plug.Plan B, drill 2 holes either side and tap them; put to holes in a bar and bolt the bar to the plug then undo.
Your idea is better because it will lessen the likelihood of swarf inside the engine block which I’m obviously keen to avoid.
Drill the hole until you're into the thicker alloy
Then find a suitable size torx and drill the hole slightly smaller than the torx, hammer the torx in
Heat the casing around the plug - I prefer a good heat gun rather than a torch as it's easy to damage the finish with a flame, then unscrew
Always worked for me
Or whack it a few times with a hammer then use a sharp chisel to start, then swap to a blunt one to knock it around
Then find a suitable size torx and drill the hole slightly smaller than the torx, hammer the torx in
Heat the casing around the plug - I prefer a good heat gun rather than a torch as it's easy to damage the finish with a flame, then unscrew
Always worked for me
Or whack it a few times with a hammer then use a sharp chisel to start, then swap to a blunt one to knock it around
tvrolet said:
Plan A, drill 2 holes either side and make up a bar with to 'pins' in it (like the sort of thing you'd undo a grinder disk with), put pins in holes and use bar to undo the plug.
Plan B, drill 2 holes either side and tap them; put to holes in a bar and bolt the bar to the plug then undo.
^^^^ This.Plan B, drill 2 holes either side and tap them; put to holes in a bar and bolt the bar to the plug then undo.
Drill & tap the flat bar with decent sized bolts (M6/8) into it, drill corresponding holes in the plug, insert and turn.
But definitely apply heat to the plug in the first instance and a bit of judicious tapping...
God luck
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