Broke a sparkplug, and how!!!

[ted655]

I'm 56, so I have broken my share of bolts. I really did it this time. I have a '69 Welcraft with a Chevy straight 6 IO. The guy is coming to buy it saturday, so since it has set for 2yrs, I started today getting it ready. Was doing OK untill I removed the last plug to spray oil into cylinders before starting engine.<br /> I had sprayed penetrating oil around the threads of the plugs,yesterday, knowing they were probably rusted. It sat overnight and I got 5 of the 6 plugs out just fine. Putting the muscle to the last and toughest plug, it broke. Not the porcelin, like usualm, but I actually seperated the plug from the threads. It broke right below the hex for the socket. Even the core with the electrode came with the plug. Now I have a ring of threads still screwed into the plug hole.<br />I have the usual easy outs (round twist-in type), but its not digging in. O please, please, I don't want to pull the head with the guy coming Saturday.<br />Is there a tool or trick? I heated the thread portion up, let it cool, then heated it up again, let it cool and sprayed PB3 on it before quitting tonight. Boy I hope there is a miricle out there somewhere. Thanks

 

[seahorse5]

Re: Broke a sparkplug, and how!!!

I use a large round EZ Out that is welded to a socket so I can use my 3/8" breaker bar. After penetrating oil soaks overnite, I tap the EX Out into the plug shell and start cranking with the breaker bar. Use a quality EZ Out, not a made in China version, and welding it to the socket allows for better control and more force.<br /><br />Good luck.

 

[ted655]

Re: Broke a sparkplug, and how!!!

How hard do you "tap" the EZout into the hole? I'm always afraid to force the thing tighter by forcing the EZout to expand it tighter. What's left is very thin but holding tight I am using a Snap On round EZout with a 12 point socket that fits snug. It's not welded. The EZout won't bite into the thing. Holds for a moment then wallows out and spins<br />How about the "nail" type of EZout, the square type?

 

[rodbolt]

Re: Broke a sparkplug, and how!!!

hello<br /> I have made my own Ez outs for that by using a square stock piece that a ground to just fit while not being so big it expanded the shell anyfurther. That is the majpr problem. if you use anything tapered it will simply wedge it tighter. good luck and keep posting

 

[Buttanic]

Re: Broke a sparkplug, and how!!!

If the easy out doesn't work you may have to split what is left of the plug with a diamond point chisel and crush it some to get it out. Then run a plug tap in to clean up the threads.Good luck.<br /><br />Buttanic

 

[tylerin]

Re: Broke a sparkplug, and how!!!

ted. is there any way you can tap it out w/ a hammer and chisel, thats if there's anything sticking outside the head. Just a thought. Good luck

 

[ted655]

Re: Broke a sparkplug, and how!!!

Yes, barely. It's #5 and we just can get a chisle on the edge of a tiny ring that is sticking out. I'm wondering about a 3 sided file, and filing a slit from the inside, to weaken it some. Do they make left hand taps? <br />.<br />No miricle tool? Shoot. Back to elbow grease. Thanks

 

[Boomyal]

Re: Broke a sparkplug, and how!!!

Whatever filing or grinding you do, try to have a vacumn nozzle at the opening to keep metal from dropping down the cylinder.<br /><br />If you have enough thickness in the wall of the plug base, keep wrapping it with a pointed punch, all around the diameter or even at an angle from inside the front opening. Be carefull not to stake the plug to the cylinder head. Repeated sharp blows will help loosen it. I wouldn't worry about using a tapered E-Z Out but keep that vacumn going. I know you have a Saturday deadline but be sure you keep it soaked good with a penetrant.

 

[Bondo]

Re: Broke a sparkplug, and how!!!

Heating the remaining piece as Hot as you can get it, Then Quench it.... Don't let it cool slowly, Quench it with water..... This will Shrink It... It'll Spin Right Out..... The little bit of water entering the cyl. can then be expelled by turning the motor over.....<br /><br />Any Rusted Bolt or Nut that can be heated HOT,+ Quenched Will Come Out/Off Quite Easily.....

 

[ted655]

Re: Broke a sparkplug, and how!!!

We soaked it with PB3 and it's set all night. Yesterday we used a propane torch. Today I will load my oxy/acte, and get a higher temp on it.<br />I was hesitent to quench it, but I will not worry about getting water in the cyl. I don't think there is enough lip to put center punch dents around, but I will get more agressive with tapping the EZout into the hole, if the quenching falls short.<br />Youse guys have given me some things I never thought of, and reinforced some things I was unsure of. Thanks everyone. I'm leaving to go do battle now.

 

[Walt T]

Re: Broke a sparkplug, and how!!!

If nothing works you can drill and helicoil.

 

[Capt Ken]

Re: Broke a sparkplug, and how!!!

Actually just heating the remaining threads of the plug and using a easy out will spin them out. Happens to me all the time. Water drips on the rear of the engines in that locations and rusts the spark plug. No need to put water on it. I use a square easy out and tap it in till good and snug.

 

[mabbott]

Re: Broke a sparkplug, and how!!!

Your selling a 34 year old boat with a motor that could be just as old. The new owner will expect some issues to repair anyway. <br /><br />I would drill and tap the hole, put in a new plug and forget about it. Use a shop vac to suck the metal filing while drilling the clearance hole. Put plenty of grease on the tap and it will probably find the existing threads in the head.....done. You are likely doing more damage with the heat from the torches.

 

[LubeDude]

Re: Broke a sparkplug, and how!!!

Bondos got the right Idea!! Dont be afraid to use enough heat to even get it red, you are not going to hurt the head! Im not talking using a cutting touch, just get it good and hot with a small tip! <br /><br />LubeDude

 

[ted655]

Re: Broke a sparkplug, and how!!!

No luck! We heated it red, quenced it. Did this several times, no go. I did find an EZout thar bites in and won't slip. Since I don't want a compound problem by breaking off the EZout, I'm not using a cheater bar. This thing is stuck!<br />Tomorrow I'm going to freeze the **** thing with a can of 132A. We are now on our 3rd type of penetrating oil. I tried to find some Krol, but no luck so far.<br />This is a ski rigged boat. It has the angle iron frame around the motor to form support for the ski hook. Getting the drill in there at the correct angle isn't possible.<br />Tell me your favorite rust buster fluids and I'll try them out. Oil, catalist, ion fluid? They all claim to be the best.

 

[Bondo]

Re: Broke a sparkplug, and how!!!

Get it Hotter,+ Redder......<br />Quenching Always Works........<br />You can bring it right up to Melting,+ Quench it.....<br /><br />The cast iron of the head will take More heat than the remaining plug....

 

[ted655]

Re: Broke a sparkplug, and how!!!

We are bringing it right to the point where it starts to melt. Tiny bubbles.<br />I'm with you..., but the block is stealing the heat pretty rapidly. We don't get much of a "Phsssssst" when we splash it. thankfully, it rained today and the guy will reschedule next week. We'll get back on it when it clears up.

 

[merc 140 pontoon]

Re: Broke a sparkplug, and how!!!

Yeah, well, I'm "the guy", and after reading this, I don't think I'm interested in your boat any longer.<br /><br />Steve<br /><br />P.S. Gotcha!

 

[ted655]

Re: Broke a sparkplug, and how!!!

 

[ted655]

Re: Broke a sparkplug, and how!!!

TA DA!! yep, heating always works. Forget the water quince. Use 132A, that shocks the heck out of it.<br /> Broken piece out, new plug in, engine running. Thanks to everyones help.