Stuck lower unit drain plug

[GatorMike]

I have two different style drain plugs in my lower unit. One has a slotted screw driver style head and the other has an allen wrench style head. I apparently over tightened the allen wrench type screw and after a year of sitting it was very tight. Here is where I screwed up. In trying to remove the plug I stripped the alen wrench hole.

So I am trying to decide how I am going to approach getting the stripped screw out, I have come up with a few options but want to be careful. I am open to suggestions. Option 1. Use my dremmel tool to cut a screw driver slot in the head of the plug and try a screw driver. Option 2. Drill a hole into the center of the allen wrench hole and try an easy out. Option 3. I doubt this would work because the drain screw is probably aluminum but I thought of inserting the allen wrench in the hole and welding it to the screw, I thought of some kind of epoxy joint but I don't think epoxy would be strong enough. 4. My final option would be to remove the lower unit and take it to a machine shop and let them try.

So does anybody have any suggestions?

 

[Cofe]

Re: Stuck lower unit drain plug

Ok Mike, Just because I like heat/welding to bust things loose, I would weld a allen wrench in the hole and the heat would help to remove the plug. I think those plugs are made of steel, a quick test with a magnet would tell.

 

[TrueNorthist]

Re: Stuck lower unit drain plug

Funny enough the welding option is one I use often, except I actually use a mig welder. The heat helps loosen the bolt and there is no need to worry about drills and extractors. Makes for a very quick job most times.

 

[boobie]

Re: Stuck lower unit drain plug

One thing you could try is get an impact screw driver with an allen head bit just a little bit larger, drive it in and maybe it will loosen. Other wise option # 4. Don't use EZ Outs.

 

[F_R]

Re: Stuck lower unit drain plug

It is stainless steel. Since you have a Dremil, I like your idea of cutting a screwdriver slot. Then use a hand impact screwdriver on it. Anybody that does any work on an outboard should have a hand impact screwdriver. It will take those drain plugs out with only one or two whacks. No problem.

 

[metriccrescentwrench]

Re: Stuck lower unit drain plug

Anybody that does any work on an outboard should have a hand impact screwdriver. It will take those drain plugs out with only one or two whacks. No problem.

^ ^ ^ Totally agree. Been there and done that.