my practice is to make sure gbox fill and drain plugs can come out before i put a box in.
fill bolt was tight, but got it off easy enough. drain pulg was slightly rounded and tight. looked like some kind of sealer on it. sprayed wd40 and let soak for 1 hour. tried to undo, no go. thought nip it up 1/8 turn then try. no good. thought id try tapping with my newly aquired nylon hammer to shock then breaker bar, no good and it strited the block bit in the pulg!!! F@%$#



now how do i get it out? just weld a block of steel or a socket onto it and try crack the seal? heat up the nut with a butane torch as well?
ive got a spare plug on another 63a... the measure the same, so should work. im at a loss now. it was rounded slightly before but now ive stuffed it... help!

you can try using bolt extractor.

http://www.autozone.com/autozone/acce ... t/Bolt-Extractor/_/N-25qe

hammer and chisel the bastard off without fuking up the thread but by the look of your previous butcher work maybe let someone else without parkinsons have a go at it.
Maybe heat around it then freeze the nut.

I admit I made it worse but it was already rounded on the edges. Its also done up too far that stuff all.thread sticking out.

I've .never seen.hammer and chisel method. Only on wheel nuts.

It was cold so the shakes were out, a scotch after I packed up helped stop them

Any way you look at it the original plug is toast.

1. you could try an easy out but my experience was dreadful and i cracked the casting of the gearbox.

2. you could weld a square solid rod into the plug

3. you could try something called a drill-out made by Alden, I have a spare 1/2 inch one i could send you

Personally I would go with #2

Marvellous!!!-

Quote:

My offerings on the scenario are either the chisel method or get a piece of solid rod (scrap metal yard) and grind it down to perfectly fit the "shape" you've created. The closer a match you can get to the actual hole, the less likely it will slip. Then cut it off so it's only about 2 cms protruding out of the nut and grind a hex onto it so you can grab it with a single hex socket.

When you're talking heat, you don't want to heat the nut, you want to warm the housing around the nut to make it expand away from the nut. it should work ok too as the alloy will expand at a lot faster rate than the nut. Don't leave it to heatsink for too long though. Heat it for 30 secs then try straight away.

Get a piece of flat bar 40 x 6.
Drill a 3/4 hole near one end.
Hold the hole end flush against the nut and weld through the hole with plenty of amps, filling the hole while making sure you are welding into the nut not just the flat bar.
Leave to cool before moving.

Use the biggest easy out that will fit inside the threads with a little meat to the outside. Drill the hole and go to town on it.

I would cut off and grind a high tensile bolt, probably around a 5/8". First cut the bolt to the length of the depth of the plug square, then grind a square on the bolt to make it a tight fit (so you have to hammer it in) then put a socket to suit the bolt head on and long bar and pull hard !

Flat bar idea is the best idea or weld a bolt to it and use the rattle gun