Sump plug head reemed out

[79beem]

So, the female hex on the plug head has finally given up. I'm thinking a screw extractor is the way to go, and taking the sump base plate( ? )  off first would probably be a wise move. Do I need to drill a pilot hole right through the plug for best purchase?Any ideas chaps?

[bruce_launceston]

Try some heat to loosen it up and hammer a large square shaft screwdriver into the recess and turn it with a spanner?
Would be easier with the sump removed thats for sure.

[tvrla]

Sometimes an imperial size allen will jam in there.

Or you could try finding a bolt with a head about the right size or slightly larger and grind to fit. Grab the bolt threads with vice grips and turn it out.

[79beem]

Thanks Bruce and wirespokes, waiting for new plug.

[tvrla]

You're welcome!

So fill us in on the gory details.  8-) What'd it take to remove it?

[Luca]

Welding a strong (grade 8 or high metric grade) nut or bolt to a rounded out plug/fastener also works nicely.  Make sure the area around the weld is free of grease/oil or other combustibles

[79beem]

Success!
After removing the sump pan and thoroughly cleaning it I secured it to the bench (bottom side up) with screws through the bolt holes, I drilled a pilot all the way through the plug .

 Then after failing to remove the plug manually with a bolt remover,cordless impact driver and a 750watt wrist snapper high torque drill . My last resort was the winner (only just) a larger bolt remover with a 10mm socket driven by an air impact wrench at 120psi.

Make sure the pan is solidly secured if you ever do this



The issue with the first three attempts was purchase on the remover as each method slipped once the remover truly bit into the plug. But having said that I'm not sure I or the driver/drills could have exerted enough force to budge the plug.  

Thanks for all the input, hope this is of help if anyone else gets themselves in this predicament.
TTFN.

[Justin B.]

Surely you hadn't tightened it THAT much on your last oil change!!??  Once you got it out are the pan threads OK?

[79beem]

Threads a tad flat but always have been,no shavings came off. Remember the pan wasn't connected to a 200kg bike using a 1/2 " ratchet. What I didn't have was a big ,tight fitting T handle for the bolt remover and I wanted to be sure I wasn't applying any sideways force. But I did tighten the new plug before I ate my spinach.