Lizard928

Use the ball bearing and welding method!

The heat from the welding should help to break the bond between the threads and whatever it is in.

ChuckD

There is no JB weld! I looked at it again and it looks great. It's just nice clean aluminum down deep. The angle of my pic is such that you can see it only on the upper side. Anyway...it's soaking. I do have a new welder, which cost more than the car. But I don't see that I could get my torch in there. I work on it intermittently due to life, but leaning toward the largest diameter extractor I can get in that will bite up as high as possible. Then go to BDC and use magnet and vac just in case. Keep you all posted.

Mike Frye

Chuck

Don't rotate the engine until you do the vacuum and magnet. You should do it again after you rotate just to be sure, but if there's anything in there you don't want any moving parts (including valves) to come in contact with foreign materials even moving in the other direction, never know, you could over rotate or it gets pinched in between a closing valve or whatever.

dr bob

Just for the fun of it, you might consider one of the freeze sprays. Depending on how thermally conductive the bond is, freezing the plug body while -gently- putting some torque to it might be enough to break the bond. No worries if some gets Into the cylinder.

Dry ice or liquid N2 handy?

76FJ55

the weld doesnt have to look pretty. would think with a mig you could get things stuck together. you would have a lot of wire out but should be able to do it. One thought might be to use an allen bolt with a head diameter that would just drop into the large diameter section of the old plug.

frankle951

It's quicker to use a bolt extractor, to get the thread out !!!!!!

rcrone928

I had the same thing happen on my 83. I used a large EZ-out with an extension and 1/2" breaker. The threaded part came out using steady pressure without to much trouble at all.

ChuckD

Porsche:37 Chuck:2. I decided to use what I had on hand. I had a dremel bit that I used to cut slots in the existing collar that was exposed once I filled hole with some tub caulk I had used recently. Then shop vacuumed it and hit it with a magnet until nothing else came out. I had some angle iron from my home made bushing installers for my other car. I cut myself a piece that to fit both the slots and a socket and it came right out. I vacuumed and hit it with my most powerful magnet tool a bunch of times as I eased it out before I actually pulled the plug out. Hoping nothing made it into cylinder. Thanks for the suggestions!

Kevin in Atlanta

There appears to be something on the threads. Probably need to use a threads chaser.

Leon Speed

Interesting thread, cool solution.

Bill Ball

Considering the limited working room and the deep spark plug hole, that's brilliant work with the Dremel tool.

Mrmerlin

I concur with Bill, excellent!

StratfordShark

Good job Chuck! I was anxious about how this thread would end.

I am also mightily impressed that you managed accurate work with a dremel deep down in the plug port. Was it on one of those flexi drive extensions or did the Dremel fit?

Also what was thinking behind filling hole with caulk? Was it just to catch as much metal particles as possible?

ChuckD

One of the responses recommended using some silicone to keep any shavings from falling into cylinder while using a large EZ-out. That made good sense to me and my caulk gun happened to have caulk in it, which I let cure for 24 hours. I had one of those carbide dremel bits for metal that made it just deep enough to catch the upper end of the threaded collar that was left. I figured I'd try it and see what happened. I thought if it didn't work that I could still obtain an EZ-Out, although buying a set like Mr. Merlin's was something I was hoping I wouldn't have to do (although I'd love to have a set). At first, I was using the angle iron but it just twisted (low carbon??) and didn't work. I decided to cut it down much shorter and just pray the shorter length would keep it from twisting and bending. I got the bright idea to find a socket that would roughly match it and it worked. Cannot wait for the next issue. I am not doing the timing belt just yet, but the new pan gasket is awaiting. That looks like a nightmare job. Dwayne's write-up looks pretty good. I also have to flip the balancer, as someone put it on backwards, making it kind of hard (impossible) to be sure timing is set correctly. But the car ran and I drove it home, so it cannot be far off as is. I appreciate the help Gentlemen!

dr bob

Very nice save! Extra points for the creative solution too!