Help Please. Core Plug Stuck fast

[simonmetalback]

Help please Gents, my Stag has just passed it's MOT - great. Get it home to find steam coming from under the bonnet. Turns out a core plug (or freezer plug if you are from the USA) has started to leak and spray on to the exhaust manifold. It's on the left head at the front. Now having just had an operation on my arm/shoulder I can't even think about trying to get it out, so I took the car round the corner to a local garage and they have tried to no avail (day and a half). So I'm getting the car back with an even bigger hole and only 1 month away from our annual club day. I'm so gutted and so close to throwing the towel in and breaking the car for spares. I live 5 miles from Bicester so you can imagine I really wanted to take the car to the Annual club day.
Two things - can any one tell me the core plug size and any tips for getting it out. I've seen these rubber core plugs in the States and was going to ship one over if I have the correct size. It would be a quick fix to at least go to the show. That is, of course, if I can get it out.
Any ideas would be really helpful gents.

[len]

hi
i have just measured mine as its on an engine stand. Its 11/4 " . It does look like a tricky one with the engine in situ as the exhaust manifold is in the way. I would imagine the manifold would have to come off to get to it . Sorry i cant help further.
Len

[marshman]

Easy to replace all the core plugs without removing anything except spark plugs. See these posts from a few years back..

http://socforum.com/forum/showthread.php?4640-So-near-yet-so-far/page3&highlight=Core+plug

Post no. 21 onwards.

Note that the core plugs have to be tipped sideways, not up or down to get them out. Use a crowbar and socket to push them in...... see the pics I posted.

Roger

[simonmetalback]

Easy to replace all the core plugs without removing anything except spark plugs. See these posts from a few years back..

http://socforum.com/forum/showthread.php?4640-So-near-yet-so-far/page3&highlight=Core+plug

Post no. 21 onwards.

Note that the core plugs have to be tipped sideways, not up or down to get them out. Use a crowbar and socket to push them in...... see the pics I posted.

Roger

Thanks Roger will get my brother up at the weekend and try try try
Cheers Simon

[simonmetalback]

Thanks Roger will get my brother up at the weekend and try try try
Cheers Simon

So before I start drilling this is what the garage have done so far, they have drilled 3 hole. I have the car at home and was going to tackle this with my brother. so and tips please.
IMG_4379.jpgCORE PLUG.jpg

[marshman]

So before I start drilling this is what the garage have done so far, they have drilled 3 hole. I have the car at home and was going to tackle this with my brother. so and tips please.
[ATTACH=CONFIG]40761[/ATTACH][ATTACH=CONFIG]40762[/ATTACH]

No need to drill!!!!!

Look at my pics!

1. remove spark plugs to allow better access.
2. USe a small cold chisel and tap the edge of the core plug, it will tip round. Hit it on one side, not the top or bottom as the casting will stop it tipping. When it has tipped round use some pipe pliers to pull it out.
3. Put some sealant around the new one - I used a bit of Tiger Seal
4. Push it in using a crowbar hooked around the manifold and a 2" bolt, find a washer to sit in the core plug to spread the load. It needs quite a bit of effort, just watch the crowbar does not slip.

I replaced all of the exhaust side core plugs in my heads in situ without removing anything except the spark plugs, didn't take long at all.

crowbar.JPG
inlet.JPG
exmid (Medium).JPG
exfront (Medium).JPG

[michael]

Hi,
As Marshman said they should come out quite easily even if it is a little awkward . I would just add put the new core plug in the freezer at the back and leave it there till the last minute . It will contract and should make it easier to tap in .
Best of luck .
Michael.

[simonmetalback]

No need to drill!!!!!

Look at my pics!

1. remove spark plugs to allow better access.
2. USe a small cold chisel and tap the edge of the core plug, it will tip round. Hit it on one side, not the top or bottom as the casting will stop it tipping. When it has tipped round use some pipe pliers to pull it out.
3. Put some sealant around the new one - I used a bit of Tiger Seal
4. Push it in using a crowbar hooked around the manifold and a 2" bolt, find a washer to sit in the core plug to spread the load. It needs quite a bit of effort, just watch the crowbar does not slip.

I replaced all of the exhaust side core plugs in my heads in situ without removing anything except the spark plugs, didn't take long at all.

[ATTACH]40763[/ATTACH]
[ATTACH]40764[/ATTACH]
[ATTACH]40765[/ATTACH]
[ATTACH]40766[/ATTACH]

Hi thanks for the tips the problem Ive got is the plug has been glued in, looks like head off now.

[michael]

I would not think it is glued in , probably has sealant on it , I'm sure if you persevere you will get it out . Taking the heads off ? Don't if you can help it , you could create more problems , manifold leaks studs breaking try and take the easiest route and tap it out . I am working on the engine at the moment and also recovering from a shoulder op . Managed to rip the stitches but was having them out this morning anyway , nurse told me off .

Keep going it WILL come out.
Michael.

[richardthestag]

even it is were glued in I have no idea what they would have used to secure it that tight, all modern glues that I have come across are pretty rubbish, no chance to securing a Ford Cortina to a billboard!. sorry but that doesnt really help does it

They are normally an interference fit. BUT if it is so tight that you risk damaging the head casting around the core plug then I don't know, maybe it is a head off

What are the odds that the rest of those new looking core plugs are about to give way! or are they 40 year old core plugs that have been given a lick of paint?

sorry for your pain, the clouds do clear though, says Richardthestag who spent all day Saturday welding up a "tiny" (more like a bloody sinkhole) hole in the front passenger footwell! arghh

[marshman]

What are the odds that the rest of those new looking core plugs are about to give way! or are they 40 year old core plugs that have been given a lick of paint?

You cannot tell from the outside, the attached pics show one I removed. From the outside it looked quite new and shiney, no evidence of any corrosion. Then look at the back of it! It was pinholed by the way.

plug.JPG

Roger

[simonmetalback]

Ok
So now I've calmed down and decided not to cut the car into thousands of pieces and fill our skip at work with the remains. I had another go at the core plug, but no luck it will not move no matter what I try. I made a puller to see if it will pull out from behind. I had pipe machined down to just smaller than the core plug size,and had it cut at a slight angle so it would put pressure only on one side, bought chisels cut them down to try and get the lip. I seem to take one step forward and three weeks back.
Last chance now i decided to to try another idea which is used quite a lot in the states. I ordered a rubber freeze plug 1/8" smaller than the core plug size so 1.1/8". When it arrived it fitted perfectly inside the new core plug (very small smile on my face now). Next task was to set the Dremel with the angle attachment and lots of 80 grit 13mm dia sanding bits and get to work grinding the back of the core plug away. As you can see from the photo it worked and all was left was the core lip.(bigger simile now).
Fitting the rubber plug was easy and with a little tread lock the job was done. Flushed and filled with water and a 30 min drive and no leaks (grin like a cheshire cat now).
Ok this is only a temp fix I only live 3 miles from the Bicester Heritage site and I was so gutted that stags from all over the UK were going to be on my door step and mine was stuck in the garage. So i'm really looking forward to meeting and seeing other club members and their cars. You can come and have a look at my rubber plug if you want Yellow stag reg 44 MAR .
Just like to thank every one for their tips and advice and look forward to seeing you all in a couple of weeks.

IMG_4461.jpgIMG_4459.jpg

[DJT]

You photo in post #13 won't display - 'Invalid Attachment'.

Good news that you are mobile again. Not heard of rubber freeze plugs before, I hope it hold out for you.

[simonmetalback]

You photo in post #13 won't display - 'Invalid Attachment'.

Good news that you are mobile again. Not heard of rubber freeze plugs before, I hope it hold out for you.

Hi Dave
Have down loaded another photo in my last post showing the freeze plug in place. Seen them used in the USA great idea if you pop a core plug. got mine from e bay. if you search you tube on freeze plugs or core plugs it will show the rubber ones.
Just about to go for another run in the car so fingers crossed.
Cheers