Expansion plug / block issue.

65Camp

Member
Hello Guys, I have a huge problem. Decided to clean up my 8N and spray a little paint on her. While I was removing things I notice the plug in the first picture was very rough looking. Touched it and my finger punched through. After cleaning it up it appears someone filled the hole with some kind of epoxy. No it’s not rust and it’s very hard. I’m guessing someone messed the casting up and it wouldn’t receive the plug. Second picture is a good one. Any suggestions on what to do? Thanks!
 

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Pop the rest out an see if a new plug will fit
If not they make rubber ones that expand with a nut
There isn’t any plug or pieces of plug in there. I’m guessing it was filled with JB Weld but not sure. I’ll take a die grinder and see if so can cut whatever it is out of there. However the outcome can’t be good.
 
There isn’t any plug or pieces of plug in there. I’m guessing it was filled with JB Weld but not sure. I’ll take a die grinder and see if so can cut whatever it is out of there. However the outcome can’t be good.
Looks like the edges of the plug are still there in your picture
Just the center rotted out
1000018598.jpg
 
Am I remembering correctly that those have a very shallow counterbore for a disc type plug and sometimes it can hard to make a new one fit properly? Might have to be creative when installing a new plug.
 
I'm going through this now with a NAA. Centers rotted out.

Remove the old plug(s). I carefully tapped them loose with a chisel and a drift, don't damage the blocks holes. They may end up inside the block, grab them them and pull out with pliers/channel locks. Clean up the plug holes in the block. A good time to flush any crud out of the block using water and a hose through upper rad hose.

NAPA and ORiellys carry new freeze plugs in steel and brass in many sizes. I measured the holes with calipers to get diameter. Maybe someone here knows the size of the plugs or part #s?.

I've not done the install yet, hopefully later this week. The holes on the NAA look OK so I'm just going to use some Permatex Aviation Formagasket on the install. If the holes look messed up post some photos and the old sages here will give better advice than I on a sealer.

Do some reading research on installing the new plugs. You want to tap them in using something nearly the same size as the inside of the plug cup. Some people have made up tools for this. If you can get at the holes, a suggestion was to use a large socket with an extension as a driver.

I'll update the thread I started on this forum after I get the new plugs in the NAA.
 
I was able to clean and round the hole up pretty good. It will never receive a metal plug. I’m going to install a 7/8 - 1” rubber expansion plug. Thanks for the help! Paul
 
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