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jamis1970
Joined: 08 Oct 2010
Posts: 56
Location: big bear lake 92315
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 Posted: Tue Nov 16, 2010 10:28 am Post subject: OH NOOOOOOOO.................... |
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went to give my car some love- (change the gear oil) only to discover the gear oil FILL plug (passenger side correct?) is completely useless. PO must have set a bomb off on it as there is nothing left for the 17 mm hex to fit onto.  I will not show you a picture of this mess as I do not wish anyone to get sick. I cant believe a 17mm hex head bolt can get so wasted. the hex head is no longer there just the remnants of some twisted schrapnel. What can I do? drill it out? the damage is so bad I dont think i can do anything to get it out. anyone have any thoughts/ideas? 79 snail
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1979 924 N/A Not Fast, but a BLAST to drive. |
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buldogo2
Joined: 13 Nov 2009
Posts: 79
Location: Nederland, Tilburg
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| Posted: Tue Nov 16, 2010 11:01 am Post subject: Re: OH NOOOOOOOO.................... |
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| jamis1970 wrote: | | went to give my car some love- (change the gear oil) only to discover the gear oil FILL plug (passenger side correct?) is completely useless. PO must have set a bomb off on it as there is nothing left for the 17 mm hex to fit onto. I will not show you a picture of this mess as I do not wish anyone to get sick. I cant believe a 17mm hex head bolt can get so wasted. the hex head is no longer there just the remnants of some twisted schrapnel. What can I do? drill it out? the damage is so bad I dont think i can do anything to get it out. anyone have any thoughts/ideas? 79 snail |
Take a dremol, and grind down 2 sides of the bold until you can fit a 16mm spanner. Then hope the bold is not corroded stuck  |
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jamis1970
Joined: 08 Oct 2010
Posts: 56
Location: big bear lake 92315
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| Posted: Tue Nov 16, 2010 11:23 am Post subject: |
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thanks ill give it a try- I was wondering if i could weld something to it to help get it out. Ill soak it in penatrating oil in the meantime. keep suggestions coming.
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1979 924 N/A Not Fast, but a BLAST to drive. |
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924 sport
Joined: 31 Oct 2010
Posts: 5
Location: Cairns Australia
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| Posted: Tue Nov 16, 2010 11:45 am Post subject: |
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Find a nut thats slightly bigger then the mangled plug head,Clean everything ,then weld inside of nut to mangled plug. 2 short welds will do it,Quelch quickly with a wet rag.Keep a fire extinguisher handy incase .Once completed, gently undo nut taping with a hammer
lightly as you go.Generally works a treat. |
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jamis1970
Joined: 08 Oct 2010
Posts: 56
Location: big bear lake 92315
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| Posted: Tue Nov 16, 2010 1:50 pm Post subject: |
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ok I talked with a mechanic friend and he said welding a bolt head was a good idea- He wanted me to ask is the drain plug steel, aluminum or something else.
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1979 924 N/A Not Fast, but a BLAST to drive. |
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Piglet
Joined: 05 Jul 2005
Posts: 2
Location: the Netherlands
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| Posted: Tue Nov 16, 2010 2:03 pm Post subject: |
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| 924 sport wrote: | | Find a nut thats slightly bigger then the mangled plug head,Clean everything ,then weld inside of nut to mangled plug. 2 short welds will do it,Quelch quickly with a wet rag. |
That's how i did it two weeks ago.... worked fine after days of messing with oil, hammer, grip pliers etc.
If you've got a welder, that's the way to go, 10 minute job....
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white 1984, 924 "non options" |
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JayZzzz4
Joined: 23 Sep 2008
Posts: 544
Location: Milwaukee, WI USA
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| Posted: Tue Nov 16, 2010 2:11 pm Post subject: |
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It might be fine just for two spot welds.... but I would be a little worried about welded anything to the transmission. Heating up extremely hot in a short time frame in one spot = uneven heating = warping , and transmissions have tight tolerances. Just a heads up, I'm sure it's fine to do. And what 924 sport said is a good idea, trans oils might cause a small fire.
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White 1987 Porsche 924S manual |
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BionicBalls
Joined: 05 Jan 2009
Posts: 642
Location: Charlotte, NC
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| Posted: Tue Nov 16, 2010 3:01 pm Post subject: |
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why not just get a good pair of vise grips and crank down on it?
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1980 924 NA
1982 931 |
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jamis1970
Joined: 08 Oct 2010
Posts: 56
Location: big bear lake 92315
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| Posted: Tue Nov 16, 2010 3:06 pm Post subject: |
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there is nothing left for visegrips to grab on to but thanks!
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1979 924 N/A Not Fast, but a BLAST to drive. |
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Joes924Racer
Joined: 03 Nov 2002
Posts: 11964
Location: Oregon, Denver Colorado native!
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| Posted: Tue Nov 16, 2010 3:06 pm Post subject: |
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Thats the ball bustin I mean knuckle bustin way,
that wont do.
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1979 porsche 924 Na
1980 porsche Turbo 931GT Replica
Have u ever driven a turbo. |
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Ozzie
Joined: 12 Mar 2005
Posts: 4448
Location: Townsville, Qld. Australia
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| Posted: Tue Nov 16, 2010 9:20 pm Post subject: |
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welding a nut or bolt into it is usually the way.
drilling may get swarf in the gear box- bad ju ju.
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Porsche 924 1984 (UK import) NA
Its AUTO and its BLACK
Montego Black on black/red
Engineer of Electro/Mechanical Systems Maintenance |
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Harm
Joined: 02 Apr 2009
Posts: 1376
Location: Holland
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| Posted: Tue Nov 16, 2010 9:41 pm Post subject: Re: OH NOOOOOOOO.................... |
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| Ozzie wrote: | | …drilling may get swarf in the gear box- bad ju ju. |
True… BTDT and cleaned it all up afterwards.
The weld road you wanna go Jamis… 
Regards, Harm.
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Porsche 924 NA 1982 LY7A/A3A3 _ Greater driving pleasure never harmed anyone. |
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Rich H
Joined: 10 Jun 2007
Posts: 2665
Location: Preston, Lancs, UK
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| Posted: Tue Nov 16, 2010 10:00 pm Post subject: |
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Casing is big and ali, the plug is small and steel, welding a couple of short tacks will barely warm the gearbox casing, it's too fast. the plug will get hot (Obviously) but it'd take a massive amount of heat to distort the case, even then being ali it's probably melt first.
It might be possible to grind a notch in the plug and tap it round with a drift and hammer?
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1994 Lotus Esprit S4 - Work in progress...
1980 Porsche 924 S2 DITC Turbo - Original spec
1978 Homo-Sapiens - Tired spec
1953 Landrover S1 - Pensioner Spec |
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MikeJinCO
Joined: 08 Jun 2010
Posts: 1245
Location: Maysville, Colorado
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| Posted: Tue Nov 16, 2010 11:40 pm Post subject: |
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X2 on Rich H, had to do that to a Ford Escort oil pan plug. It is a huge case for the amount of welding involved. Heat in the case is not an issue.
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Mike
'67 MG Midget Dp
'71 Ocelot Dsr Kawasaki 1000(under rebuild) |
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BionicBalls
Joined: 05 Jan 2009
Posts: 642
Location: Charlotte, NC
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| Posted: Wed Nov 17, 2010 3:14 am Post subject: |
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If you're worried about heat, you could try using some JB weld or some other epoxy.
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1980 924 NA
1982 931 |
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