Help! Drain plug head broke off! How do I get the threaded part out?!?!?!

Help! Drain plug head broke off! How do I get the threaded part out?!?!?!

Hey all!

I purchased a magnetic drain plug and put it in last oil change. I
just went to change the oil (97 KX250) and the plug head just broke
right off! Surprisingly 'casue I have a skid plate so I highly doubt
anything (rock, etc.) caused it! Now I have the rest of the plug
(threaded part) still in the cases. I've never used a tap-and-dye (or
is it die) but I guess this is as good a time as any to learn. Does
anyone have any suggestions or advice? A better alternative? Thanks
in advance!

Scott

Re: Help! Drain plug head broke off! How do I get the threaded part out?!?!?!

On May 14, 5:37=EF=BF=BDpm, nos...@my,net wrote:
> Hey all!
>
> I purchased a magnetic drain plug and put it in last oil change. =EF=BF=BD=
I
> just went to change the oil (97 KX250) and the plug head just broke
> right off! =EF=BF=BDSurprisingly 'casue I have a skid plate so I highly do=
ubt
> anything (rock, etc.) caused it! =EF=BF=BDNow I have the rest of the plug
> (threaded part) still in the cases. =EF=BF=BDI've never used a tap-and-dye=
(or
> is it die) but I guess this is as good a time as any to learn. =EF=BF=BDDo=
es
> anyone have any suggestions or advice? =EF=BF=BDA better alternative? =EF=
=BF=BDThanks
> in advance!
>
> Scott

There is a tool called an "easy-out". Easy to use and you shouldn't
have any problem.

Hank <~~~not easy, but can be had

Re: Help! Drain plug head broke off! How do I get the threaded part out?!?!?!

On Wed, 14 May 2008 15:37:14 -0700, nospam@my,net wrote:

>Hey all!
>
>I purchased a magnetic drain plug and put it in last oil change. I
>just went to change the oil (97 KX250) and the plug head just broke
>right off! Surprisingly 'casue I have a skid plate so I highly doubt
>anything (rock, etc.) caused it! Now I have the rest of the plug
>(threaded part) still in the cases. I've never used a tap-and-dye (or
>is it die) but I guess this is as good a time as any to learn. Does
>anyone have any suggestions or advice? A better alternative? Thanks
>in advance!

Get an EasyOut or equivalent. Most auto parts stores should have
them fairly cheap. You drill a smaller hole part way into the
plug and then use the tool to back it out. If there's any of the
head left on there at all, you might try tapping it with a chisel.

http :// www .irwin,com /irwin/consumer/jhtml/browse.jhtml?catId=IrwinCat100497



http :// indoors.pricegrabber,com /mechanics-tools-tool-sets/p/1403/form_keyword=easy%20out%20tools/rd=1/mode=ink_kwfeed_30/skd=1/st=query/





----
Team NCS Off Road
----

Re: Help! Drain plug head broke off! How do I get the threaded part out?!?!?!

Easy Out works great until you twist it and the easy out breaks off
leaving a hardened piece of steel in the hole. It can be removed at
this point but it takes a cutting torch. OF

Re: Help! Drain plug head broke off! How do I get the threaded part out?!?!?!

On Wed, 14 May 2008 15:58:15 -0700 (PDT), oldfart
<alan.westcoast@gmail,com > wrote:

>Easy Out works great until you twist it and the easy out breaks off
>leaving a hardened piece of steel in the hole. It can be removed at
>this point but it takes a cutting torch. OF


Damn. How tight can a drain plug be in in the first place? I
can't imagine breaking off an Easy Out, but I'm guessing you
couldn't either before whatever happened to make you write the
above...


----
Team NCS Off Road
----

Re: Help! Drain plug head broke off! How do I get the threaded part out?!?!?!

scrape wrote:

> On Wed, 14 May 2008 15:58:15 -0700 (PDT), oldfart
> <alan.westcoast@gmail,com > wrote:
>
>>Easy Out works great until you twist it and the easy out breaks off
>>leaving a hardened piece of steel in the hole. It can be removed at
>>this point but it takes a cutting torch. OF
>
>
> Damn. How tight can a drain plug be in in the first place? I
> can't imagine breaking off an Easy Out,

Long ago we broke the tiniest one in the 3-piece set. Always meant to
take it back to Sears and get a new one, and now the whole thing is lost :-)

> but I'm guessing you
> couldn't either before whatever happened to make you write the
> above...

I always worried about stripping the threads in the hole rather than
breaking the bolt.

--
Cheers,
Bev
==========================================================An organizer for the "Million Agoraphobics March" expressed
disappointment in the turnout for last weekend's event.

Re: Help! Drain plug head broke off! How do I get the threaded part out?!?!?!

>>Easy Out works great until you twist it and the easy out breaks off
>>leaving a hardened piece of steel in the hole. It can be removed at
>>this point but it takes a cutting torch. OF
>
>
> Damn. How tight can a drain plug be in in the first place? I
> can't imagine breaking off an Easy Out, but I'm guessing you
> couldn't either before whatever happened to make you write the
> above...

Oh man, I'm flashing back to the easy out broken off in an exhaust manifold
stud (225 slant six)...
I have tremendous fear of those brittle tools. Funny how hardened stuff
doesn't like to flex.

In a similar situation today I would go with reverse fluted drill bits (
which cut while spinning counterclockwise), working my way up closer and
closer to the stud size. Provides heat too. Eventually the bit spins out the
threaded remains of the offending fastener. This is probably less practical
on a large plug because the reverse bits are hard to find and spendy too.
But it works great. Still, there's the same risk of breaking the hardened
bit off in there.

Craig is right, you can aften get good results just patiently tapping on a
strategically placed chisel thereby getting a couple degrees of spin with
each tap.

Good luck. Let us know.

-Dean
P.S. Beer usually helps.

Re: Help! Drain plug head broke off! How do I get the threaded part out?!?!?!

On May 15, 6:35 am, "Dean H." <m...@groove.calm> wrote:

> P.S. Beer usually helps.
^^^^

You misspelled "always".

Re: Help! Drain plug head broke off! How do I get the threaded part out?!?!?!

> Damn.  How tight can a drain plug be in in the first place?  I
> can't imagine breaking off an Easy Out, but I'm guessing you
> couldn't either before whatever happened to make you write the
> above...

I'd have to imagine that once the head breaks off, there isn't any
tension on the threads anymore, so the force required is just to break
just the corrosion. An oil plug shouldn't have any corrosion, so I'd
expect the thing to slide right out.

JayC

Re: Help! Drain plug head broke off! How do I get the threaded part out?!?!?!

On Wed, 14 May 2008 15:58:15 -0700 (PDT), oldfart
<alan.westcoast@gmail,com > wrote:

>Easy Out works great until you twist it and the easy out breaks off
>leaving a hardened piece of steel in the hole. It can be removed at
>this point but it takes a cutting torch. OF

The larger the easy out, the less likely a certain amount of force will
snap it. With no head on this thing, there is no "bolt stretch" holding the
thing in place. That leaves either thread locking compound (you wouldn't do
that though:) or dissimilar metal corrosion. You might break the latter
free with some judicious use of a punch... tap the stud near but not on the
threads as you don't want to peen them over. That would be like adding
thread lock:)

Someone suggested milling a screw driver slot with a Dremel and if you can
go that route, that is probably the easiest and least risky. Whack the bolt
with a bunch (it really works) and unscrew the broken stud... again, there
should be no resistance to backing it out once appropriately broken free.

Escalation from that point would involve an easy out. Do make sure you get
one large enough to not break. Again, this is not a bolt that's been in
place for 200 years and we all know you didn't thread lock it:) Get an easy
out that's maybe 50% of the diameter of the stud to be safe. Since you have
the internal engine environment just on the other side of this thing, you
want to not send a lot of debris inside with the drilling operation. You
might not have to drill, but easy outs are tapered and oil bolts are
typically short and you might need to punch through if the geometry
dictates. I personally would try and drill a PARTIAL DEPTH pilot hole first
without punching through. Then I'd go with a nice sharp drill at the final
size (note that easy outs will dictate what size drill to use). For this
second drilling operation, I'd fill the flutes of the drill with grease to
catch the shavings and go very slowly... nibbling away and re greasing. The
magnetic stud will probably just keep all the debris connected to it anyway
but it doesn't hurt to be safe.

Good luck!

Mike


--
Mike W.
96 XR400
70 CT70
71 KG 100 (Hodaka-powered)
99 KZ1000P (training)
99 KZ1000P (rider)
00 Beta Rev-3

Re: Help! Drain plug head broke off! How do I get the threaded part out?!?!?!


"oldfart" <alan.westcoast@gmail,com > wrote in message
news:9bf83935-864b-4dc4-aedd-b14f23ae091c@y38g2000hsy.googlegroups,com ...
> Easy Out works great until you twist it and the easy out breaks off
> leaving a hardened piece of steel in the hole. It can be removed at
> this point but it takes a cutting torch. OF

In combination with the EZout, use left hand drill bits. In most cases, the
drill bit will catch while drilling, and back the bolt out.

Re: Help! Drain plug head broke off! How do I get the threaded part out?!?!?!

HellSickle wrote:

> "oldfart" <alan.westcoast@gmail,com > wrote:
>> Easy Out works great until you twist it and the easy out breaks off
>> leaving a hardened piece of steel in the hole. It can be removed at
>> this point but it takes a cutting torch. OF
>
> In combination with the EZout, use left hand drill bits. In most cases, the
> drill bit will catch while drilling, and back the bolt out.

Excellent idea, providing left-hand drill bits actually exist...

--
Cheers,
Bev
++++++++++++++++++++++++++++++++++++++++++++
No lawyering. Prosecutors will be violated.

Re: Help! Drain plug head broke off! How do I get the threaded part out?!?!?!

The Real Bev says:

> Excellent idea, providing left-hand drill bits actually exist...

http :// www .mcmaster,com /

Search drill, go down the list to Left-hand.
Or just go to page 2383, bottom of the page.


Go fast. Take chances.
Mike S.

Re: Help! Drain plug head broke off! How do I get the threaded part out?!?!?!

sturd wrote:

> The Real Bev says:
>
>> Excellent idea, providing left-hand drill bits actually exist...
>
> http :// www .mcmaster,com /
>
> Search drill, go down the list to Left-hand.
> Or just go to page 2383, bottom of the page.

Wow, if I only had a multiple-spindle drilling head I'd be in fat city!

That's like the story about the little old lady complaining to the cop
about being able to see the naked man next door if she stood on the toilet.

--
Cheers,
Bev
1010101010101010101010101010101010101
What do you think you're doing, Dave?
-- Hal 9000

Re: Help! Drain plug head broke off! How do I get the threaded part out?!?!?!

oldfart wrote:
> Easy Out works great until you twist it and the easy out breaks off
> leaving a hardened piece of steel in the hole. It can be removed at
> this point but it takes a cutting torch. OF

True. A good 30 years ago a buddy of mine and i assure his mother we'd
change that blown bulb of the front turn signal of her Opel Rekord.
First we sheared off the head of the - as we claimed - already rusted
philips screw. Next we tried to drill out, more precisely drill away,
the screw, breaking the drill in mid action. Consequently we tried to
drill out the drill, only to find it very hard to keep the new drill
pointed at the core of the broken off one. Which caused us to "hit"
the softer parts around the stuck drill, ruining what was left of the
philips screw's "hole".

This picture always comes to my mind when someone claims to "have
screwed" some repair task.

Since then i am very wary of any EasyOut type tools, especially when
the threading sheared off while unfastening a bolt and even more so
when this happens a couple windings down the hole. This shearing off
process tends to create sharp edges perfectly desigend to prevent any
kind of reverse turning.

The key to successfully easy out something seems to be to pick the
correct OD of the drill out hole:
Too small and one will break the easy out
Too big and the wall of the bolt will break when easying out.

YMMV
Rowdy