Broke a blue drain plug

[jmauld]

Any advice on how to get the leftover part out of the cool fuel unit?

 

[Sun Chaser]

I used an easy out when I had the same problem.

Glenn

 

[jmauld]

Not having any luck with my easy out. I think it’s expanding the plug and making it more stuck.

Edit: actually my easy out just dug all the way through it

 

[Strecker25]

for next time, hot flathead screwdriver pushed into broken of threads then let it cool. Usually backs right out

 

[jmauld]

Any idea on what to try now?

I’m just breaking off chunks of it at the moment.

 

[jmauld]

Is there a thread chaser that I can use to push out the remaining plastic bits?

 

[Strecker25]

Is there a thread chaser that I can use to push out the remaining plastic bits?

sorry, I thought you meant you got it out. Is it a blind hole or can you see it? If you’re seeing little pieces come out you’re probably going to have to go at it with a small pick to chip away at all the pieces

 

[jmauld]

I can kind of see it, but it’s mostly a blind hole

 

[randmhall]

Is there a thread chaser that I can use to push out the remaining plastic bits?

Yes, there is a thread chaser. Just a standard tap works great. it has been a couple years, but I think it is just a 1/2" tap from the hardware store. Mine was seized, so I drilled it gently with a 3/8 followed by the tap for the pieces stuck in the treads.

 

[douglee25]

Stubby screw driver, use torch to heat it up, push into the plug, let cool, back out.

 

[jmauld]

Just in case someone finds this in a future search.

if you are an idiot like me and screw the plug so bad that you cant do the hot screwdriver trick you can purchase a 1/2-13 tap.


VERY Carefully use a 25/64 drill bit, (I started out four sizes smaller) to remove most of the old plug. Be certain that you’re not drilling into metal. I used a small vice grip for this so that I didn’t have too much leverage and could feel the difference between metal and plastic. Don’t use a drill.

Once the drill bit goes through you can then carefully dig the remaining plastic out with the tap. Put the plug back in and let pressure build up a couple of times removing the plug so that it washes out any leftover bits

 

[jmauld]

Also I found out at about 10:00 last night that my seacock for the starboard engine is failed in the open position. Which meant that drain was slowly dripping water into my bilge. I know my bilge pumps could keep up with that leak but I couldn’t leave it.

so I made a temporary plug. I used a small rubber stopper, drilled a hole in it and inserted a screw. The stopper with the screw all the way in didn’t let any water drip.

probably not needed but it let me sleep last night.

 

[bfernald0]

I've had the blue drain plug break off several times. I used a screwdriver pick to dislodge and break off chunks. Once you've reduced the surface area a tad, you can generally insert the pick into the threads and turn the remainder of the insert out. Concentrate on breaking out one side of the plug. It becomes easier at that point to turn the rest on the threads. It's aluminum, so you want to be careful. Harder to do any real damage with a pick. A drill or a flat head makes it easier to do permanent damage to the threads.

 

[wyrman]

Hardin sells stainless plugs.

 

[CaptRonn]

Hardin sells stainless plugs.

I have to wonder about the dissimilar corrosion that could be set up by screwing in a stainless plug. The cool fuel housing is aluminum correct?

 

[bfernald0]

I have to wonder about the dissimilar corrosion that could be set up by screwing in a stainless plug. The cool fuel housing is aluminum correct?

My mechanic said the same thing. You'll never get it out once the dissimilar metals work their magic.

 

[jmauld]

I'm just buying all new *mercruiser blue plugs and keeping the old ones for spares.

This one that I broke was a knockoff.

Do you guys lube these threads with anything?

 

[juggernaut1]

Hardin sells stainless plugs.

That's what I installed in mine and coated them in Duralac to combat the dissimilar metals problem.

 

[Rob WIcha]

How are the stainless plugs with Duralac working out? I want a better solution than the blue plugs that keep breaking off!

 

[Bill Curtis]

This is 3rd engine I put the Hardin S/S plugs in and haven't had a problem with any of them since.