stripped allen on oil tank...best way to remove?

[Vintage914Racer]

When changing my oil I managed to strip the allen bolt on my oil tank. Its recessed so I have nothing to grab onto with a vise grip. Any advice on removal?

[OldTee]

The allen is the same size as a bolt head. Find a nut a little larger than the plug recess. File or grind the edges (ends or faces) of the nut to fit into the recess. Gonna take some work. Then put the nut on a bolt and have someone weld the nut to the bolt. Now you have a tool that should have enough purchase to back the allen out. I would buy a tube of diamond paste (altizemers is taking over here and I cant remember the name of it) and it will help with the grip of the nut and bolt tool. Then clean the allen as clean as you can get it with brake clean, then heat the allen some and twist away. Good luck. Order a new plug.

[Porsche_monkey]

OldTee is right.

If that fails mig weld the nut in. It is a steel plug, right?

[rusnak]

I've used something called a nipple extractor. It's used to remove pipes, and you can find them in either Harbor Freight or your local OSH. Old Tee's method sounds kinder to the metal, so I'd try that first, and use the nipple extractor as a Plan B.

[Rich Lambert]

This is a long shot, but it's worked for me before. Try cutting the very end of the allen wrench off. Most allen wrenches have a very slightly tapered end and cutting that off will allow the wrench that extra little bit to catch some undamaged bolt.

[Fishcop]

Ditto to Rich's advice - it may give you the purchase you need.

[jbrand540]

Occassionally I have had good luck using a torx socket, especially on larger allens. Try taking a Torx bit that is roughly the same size or slightly larger then the stripped allen opening and hammer it into the bolt. Typically one you have stripped it the head of the bolt will give a bit and allow the torx teeth to dig in.

[911pcars]

Even if the female hex is in excellent shape, the oil tank plug can be very difficult to remove. Overtightening it previously doesn't help either. Use a 3/4" dr. socket and flex handle on your female-to-male hex adapter for less flex and a 4' long pipe for added leverage.

Then there's ultimate torque with a large impact gun. It might work or it might create more damage (and instant oil drainage) if used overzealously.

One episode of experiencing a stubborn oil tank drain plug convinced me to replace it with a Fumoto ball-valve. No leaks, no grunting.

Sherwood

[Eric Coffey]

Originally Posted by jbrand540

Occassionally I have had good luck using a torx socket, especially on larger allens. Try taking a Torx bit that is roughly the same size or slightly larger then the stripped allen opening and hammer it into the bolt. Typically one you have stripped it the head of the bolt will give a bit and allow the torx teeth to dig in.

Yep, you can sometimes get lucky with the Torx bit method. Or, you can invest in a set of spiral extractors:

[Mr9146]

Grab the drain plug itself with a pair of STRAIGHT JAW vise grips as hard as you can - grab it like you would grab a nut ... horizontally and not vertically. There should be plenty of plug to grab on to and it shoud break loose fairly easily. Give the grips one good smack and the plug should break loose.

It doesn't matter if you mangle it because you need a new one anyway.

[Vintage914Racer]

Thanks for all the help. I tried the torx method and easy out method with not success. The plug is aluminum and the torx just ate it up from the inside. The plug is only recessed about
.5 mm so there is no way I can get a vise on it either...