Broken plug update
Thread Starter
Advanced
Joined: May 2018
Posts: 74
Likes: 45
From: Upstate NY
Broken plug update
Gents,
I tried one more time this weekend to get the plug shell out and I succeeded! Used a 12.5MM drill bit, greased and drilled out the major portion of the shell save for the threads. Ran a greased 14Mmx1.25 tapered tap cautiously, about 1/2 turn at a time, removed the tap, cleaned the threads,regreased it, rinse repeat. Took about 45 minutes to run the tap through and it took out the remaining steel threads of the plug. Borscope showed clean threads in the cylinder head and no debris in the cylinder. Swabbed the grease out of the plug hole with lacquer thinner, magnet to pull out any metal parts, nothing stuck to it. I spent about 1/2 hour cleaning out the spark plug hole. Threaded new plug in by hand, then torqued to 22 ft. Lbs. per Porsche spec. Started car, some smoke from the penetrant, no noise, strange sounds. Smoke cleared up, car idled, sounded fine. I was extremely lucky and thankful I had a machinist who helped me along the way with his skill. Putting the covers back on, take the car for a drive first time in over 3 months! Knowing what I know now, this kind of job is best left to the pros. I was stubborn and determined to see it through with the help of friends and my wifes support. All tole, I spent about $300.00 on drills, tools, and machinist labor. Better than thousands of $$$ to pull the engine and head. But that being said, I would NEVER attempt this repair again. If you intend to change plugs yourself, raise the rear of the car to scoot under it, remove the rear plastic cover and use a 6 inch 3/8 extension to get a straight shot at plug #1&4. Not wonky universals, long extensions blah, blah. Many thanks for your interest and support guys. Have a great summer, I know I will!
I tried one more time this weekend to get the plug shell out and I succeeded! Used a 12.5MM drill bit, greased and drilled out the major portion of the shell save for the threads. Ran a greased 14Mmx1.25 tapered tap cautiously, about 1/2 turn at a time, removed the tap, cleaned the threads,regreased it, rinse repeat. Took about 45 minutes to run the tap through and it took out the remaining steel threads of the plug. Borscope showed clean threads in the cylinder head and no debris in the cylinder. Swabbed the grease out of the plug hole with lacquer thinner, magnet to pull out any metal parts, nothing stuck to it. I spent about 1/2 hour cleaning out the spark plug hole. Threaded new plug in by hand, then torqued to 22 ft. Lbs. per Porsche spec. Started car, some smoke from the penetrant, no noise, strange sounds. Smoke cleared up, car idled, sounded fine. I was extremely lucky and thankful I had a machinist who helped me along the way with his skill. Putting the covers back on, take the car for a drive first time in over 3 months! Knowing what I know now, this kind of job is best left to the pros. I was stubborn and determined to see it through with the help of friends and my wifes support. All tole, I spent about $300.00 on drills, tools, and machinist labor. Better than thousands of $$$ to pull the engine and head. But that being said, I would NEVER attempt this repair again. If you intend to change plugs yourself, raise the rear of the car to scoot under it, remove the rear plastic cover and use a 6 inch 3/8 extension to get a straight shot at plug #1&4. Not wonky universals, long extensions blah, blah. Many thanks for your interest and support guys. Have a great summer, I know I will!
Nordschleife Master
Joined: Oct 2015
Posts: 5,723
Likes: 2,290
From: Zuffenhausen, Georgia
A W E S O M E N E W S!!!!!!!! 
Congratulations! And, finally some positive news around here for a change!
Please take some pictures, maybe a video celebration?? ha! Love it!
Congratulations! And, finally some positive news around here for a change! Please take some pictures, maybe a video celebration?? ha! Love it!
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Rennlist Member
Joined: Jun 2021
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I was following this thread regularly here and on P9. nice update!!
Awesome! That is some careful operating you did. I think I'd be sweating profusely when using the tap.
So just running the tap through pulled out the shell of the plug? No need for an easy out or anything? Nice.
Awesome! That is some careful operating you did. I think I'd be sweating profusely when using the tap.
So just running the tap through pulled out the shell of the plug? No need for an easy out or anything? Nice.
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Joined: Nov 2019
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From: Jersey Shore
I’ll admit this one had me intrigued. It was beginning to feel like episode after episode of Gilligan’s Island. New gadgets and contraptions but rescue still left to the next episode. I was happy when Gilligan, the Skipper and gang we’re finally rescued. I’m happy for you too. Now I need to start watching some reruns.
