Re: Block drain plug on H

Posted by ScottyHOMEy on April 02, 2009 at 07:18:34 from (71.241.194.27):

In Reply to: Block drain plug on H posted by DTK on April 02, 2009 at 06:28:01:

Yep, that's a different bear. Much more apt to be corroded in and twist off.

As long as we're talking about a drain on the block and not the pipe down to drain the radiator, the same general rules apply. Any drillng should be with a left-twist bit, and the DrillOuts are preferable in my book to an EZOut.

Keys to success that dont' include welding a nut on top (a GOOD option if you're equipped to do it) will include heat AND a lubricant before you start any drilling. A hand-held householder propane torch will do it, but a bottle of Mapp gas on the same torch will be hotter and better. First a good general heating of the bolt and the surrounding area will do a lot to break up and crumble some of the crystalline structure of the solid mass of corrosion binding the thread. Heat it like that a time or two (allowing it to cool in between times) until you start to see some edges just beginning to glow a little when you take the flame away. The second time you heat it, spary a little PB Blaster or another spray-type penetrant onto it after it has cooled a little bit but is still good and warm. Put as much to it preiodically as it will take. It may sizzle a little but you should see it draw into the thread some as it cools more.

From there, I would let it cool down completely before doing any drilling I planned to do but not try extraction yet. Let the heat from the drilling do it's work and let it cool down again. Then, just before attempting to actually get it out (DrillOut, EZOut, chisel) I'd light the torch back up and apply heat a couple inches away from and all around the bolt, the idea being to do what you can to expand the hole without expanding the bolt any more than you can help. Then go for it. It may take some "wash, rinse,repeat" with the heat and the lubricant. I've never had any two busted bolts come out the same, but they will come out.

Welding a nut on top will work well, too, though that might be difficult if the plug is cast goods, and the heat from the welding will have as much or better effect than any of the heat with a torch that I described above.

Last word of caution, especially if you elect to go with the chisel, is to keep in mind at all times the (tongue-in-cheek!!!) hammer rule, which reads, "Hit with progressively bigger hammers until you break something, then back down one size."

Good luck, and please let us know how you make out.

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