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Any smart ideas? (auto repair)

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cubber
Posts: 1933 - Karma: 638
VW jetta, TDI

so a glo plug broke off, between the threads and the hex.
After soaking PB Blaster all over it for a week, I drilled out the center, tried an easy-out with no luck.

Then I torched the head just around the plug til it was hot to the touch, immediately sprayed Freeze-Off into the plug and tried easy-out again, still no luck.

Another option i'm hesitant to try is heating it, and melting a candle onto it. supposedly this is like braising pipe, and the heat will suck the wax into the threads. this seems super messy, so i haven't tried yet.

so if you took the time to read this and have a suggestion, throw it at me! Otherwise i'll have to pull the head (+timing system agh) and have the head planed, extra $300 in parts and 2 days more. Thanks ahead of time!
Dec 20 2011 2:14PM
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cubber
Posts: 1933 - Karma: 638
i already wasted a full day on this one plug and i'm all frustrated, just looking for home remedies
Dec 20 2011 2:16PM
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MrWadsworth
Posts: 29 - Karma: 10
You sound like you know what you're doing, but I'm gonna check anyway. You say you drilled the plug. Did you drill all the way through? Because if you did, then you have to pull the head anyway. You now have metal shavings in your cylinder.


Dec 20 2011 2:43PM
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DANETRON
Posts: 6671 - Karma: 137
.once i broke off the head of  an exhaust manifold bolt. I welded an old shitty socket extension to it. and it worked pretty well. maybe you could do it with the glow plug? just a thought idk if it would work in this situation but it did for me
Dec 20 2011 3:08PM
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cubber
Posts: 1933 - Karma: 638
can't blame you for checking but i did only drill halfway into the plug, i don't dare go much farther cause i don't think i'm centered
Dec 20 2011 3:33PM
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cubber
Posts: 1933 - Karma: 638
we thought about that a bit too, but won't it heat the aluminum head too much and warp it?
Dec 20 2011 3:34PM
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DANETRON
Posts: 6671 - Karma: 137
hmmm didnt think of that. maybe some quick tacks and it wont heat too much...?
Dec 20 2011 4:13PM
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Hoppy
Posts: 685 - Karma: 95
Can you tap an 8mm bolt into it?
Can you grind/cut slots into it and maybe chisel it out? (hitting it counter clockwise)
Dec 20 2011 5:46PM
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MrWadsworth
Posts: 29 - Karma: 10
This maybe?

http://www.peachparts.com/Wikka/OM606BrokenGlowPlug
Dec 20 2011 5:48PM
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Broken_Rides
Posts: 334 - Karma: 224

You already have a hole drilled in the centre of the plug.  (Redhole)

Click for larger image

Drill 2 smaller holes on opposite sides of the first hole.(2 Greenholes)

Keep the holes off the thread.

Grab a big Flathead screwdriver, Hammer it in the hole 'til it's stuck.

Grab the screwdriver with a pair of vice grips, and twist it out, keep pressure down on the screwdriver while you do it. You might need a lever bar.

Dec 20 2011 6:16PM
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PlaygroundRapist
Posts: 1307 - Karma: 26
Use epoxy to glue a metal O-ring on it. Then it can easily be pulled out.

A french garage did this with my old Audi a couple of years ago that had the same problem.
Dec 20 2011 6:21PM
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Darth.Maul
Posts: 2472 - Karma: 652
I'd tack a bar to it and then tack another long bar for a handle so you can get lots of leverage... Just be careful with that much torque so you don't strip the threads...
Dec 20 2011 7:29PM
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cubber
Posts: 1933 - Karma: 638
The hole is 1/4 inch so i think this might be the only option, i'll try it tonight with a reverse thread bolt instead of a o-ring.. +bananas for everyone, thanks!
Dec 20 2011 8:05PM
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cubber
Posts: 1933 - Karma: 638
we're too scared to even tack it cause the hole is so close to the edge of the head, it's super easy to overheat it then, but hopefully the epoxy trick will cut the butter
Dec 20 2011 8:07PM
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SPskier543
Posts: 2413 - Karma: 324
jb weld a bolt onto the top, remove with a socket. i doubt it would be easy to get a welder to where it is without burniong or melting something, not sure though cuz iv never worked on diesels
Dec 20 2011 8:11PM
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cubber
Posts: 1933 - Karma: 638
you and me sir, are on the same page!
Dec 20 2011 8:12PM
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.KYLE.
Posts: 1891 - Karma: 59
What is a glo plug....
Dec 20 2011 11:13PM
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Broken_Rides
Posts: 334 - Karma: 224
It heats up the ignition parts in a diesel motor.
Dec 21 2011 1:53AM
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cubber
Posts: 1933 - Karma: 638
my dad came over to help me out, here's what we did (for future reference?)

took out the neighboring glo plug, found drill bit that fit exactly in that hole.
used drill 1/32 down from that size, drilled 3/4 inch (total) into the broken plug.
pounded a square easy-out into the drilled hole

This time the easy-out broke the wall of the glo plug and freed the plug!

thanks everyone for the help
Dec 21 2011 9:20AM
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