Oil galley plug fix?

[doctorjj]

So, I read a lot of nightmare posts on here about that plug in the head blowing out and losing all the oil very quickly. I also read about how to tap it and plug it, including some posts about breaking taps and other nightmares with that process.

So, I came up with a "fix" for all of us out there whose plug is still in place and working fine and aren't giddy about ripping out a functioning part at the risk of creating a problem. I decided to manufacture a piece of metal that would prevent any catastrophic failure of this plug. I had a lot of little strips of titanium laying around. They are about 1.5" long, 0.5" wide and 1/16" thick. I bent one in a Z shape and clamped it down under the bolt next to the plug where it is blocking the aluminum plug from being able to back out. What do you guys think? Good idea? Stupid? Should just bite the bullet and tap and plug the hole?

Here's a couple of pics.

 

[GLTHFJ60]

I would say that if all of us had spare strips of titanium laying around that your fix would be great for all of us.

I do not have any spare titanium lying around, so I won't be using this method, but I feel it will work well for you.

 

[doctorjj]

I would say that if all of us had spare strips of titanium laying around that your fix would be great for all of us.

I do not have any spare titanium lying around, so I won't be using this method, but I feel it will work well for you.

Anyone who wants a strip can have it free. PM me your addy and I'll stick one in an envelope. However, I suppose any piece of metal would work. I just happened to have these laying around and they seemed to be about the right size.

 

[GLTHFJ60]

Anyone who wants a strip can have it free. PM me your addy and I'll stick one in an envelope. However, I suppose any piece of metal would work. I just happened to have these laying around and they seemed to be about the right size.

Haha, I apologize. I didn't mean to come off as too much of a dick, but when I read it all I could think about was that you had some titanium strips lying around your shop. By the way, why do you have titanium lying around?

That fix looks good! Over time I can see a small strip like that flexing out of the way after going through so many heat cycles, but if you use a strong metal like, well titanium, I'm sure it would last for quite a while.

Then again, considering that all one has to do to tap that hole is remove one head stud, I think I'd rather just do that for a more permanent fix.

 

[doctorjj]

The strips were from a previous research project, (long story). Anyway, they aren't much good for anything else. Maybe because I had them laying around was what made me think of this idea, trying to come up with some use for them.

Derek and Jason, yours are on their way. Let me know how it works out or if you have any questions when you start trying to make this thing.

 

[doctorjj]

As of now, all the requests for strips have been mailed out. I, actually, don't have any more readily available. I have a ton more of them somewhere, but I just moved. If I find them, I'll post and let everyone know more are available. For those who I sent strips to, please let us know how it works for you.

 

[ProwlerDriver]

Thanks Doctor! Hopefully this will help keep any problems at bay.

 

[jys381]

What's a redneck doing with titanium?

Just kidding!! Good idea, I might try this too as a precaution until I have the engine out and can reach the spot easier.

 

[JLH911]

received mine today!


Thanks for your generosity

 

[doctorjj]

I only revived this old thread because I found quite a few more of the titanium strips in my garage. Anyone else who wants one, PM me and let me know. I'll send you one, ASAP.

BTW, anyone who got one earlier have any feedback on how its working? Mine seems to be working great.

 

[Bryan062087]

Can you explain how this works a little better? Sorry, still not understanding completely.

Did you weld this piece of titanium to the head? How is it held on, is it just clamped behind that one bolt. How exactly is it clamped? I don't understand. Whats holding it down on the other (right hand) side?


Could you just coat the plug face with JB Weld, welding in place to the block?

 

[doctorjj]

Can you explain how this works a little better? Sorry, still not understanding completely.

Did you weld this piece of titanium to the head? How is it held on, is it just clamped behind that one bolt. How exactly is it clamped? I don't understand. Whats holding it down on the other (right hand) side?


Could you just coat the plug face with JB Weld, welding in place to the block?

It is bent into, basically, a Z shape. The one leg of the Z is clamped under the bolt. It is held in just by the friction of the clamping force. The other end of the Z just holds the factory aluminum plug in place. I suppose you could put some JB weld on the leg of the Z that faces the aluminum plug, but it's not necessary. The purpose of this is just to prevent a catastrophic ejection of the aluminum plug that some people have had happen to them.

 

[alaska60]

I got a piece of this from doctorJJ back in november. He even put a mark on it where to bend. simple and resourceful idea. it is on "dusty" (85 fj60 bone stock with luggage rack) "PIECE OF MIND NOW"

 

[Mark W]

Be aware that often the plug leaks without moving outward. And if it does dislodge as well it will leak a LOT as it shifts out the bore and into this stop you have made. It is better than nothing but do not let if give you a false sense of security.

Best answer is to tap the bore for a threaded plug. not really difficult. next best is to simply put a new expandable plug in place....

You could also braze over the existing plug in the hole.


Mark...

 

[alaska60]

Be aware that often the plug leaks without moving outward. And if it does dislodge as well it will leak a LOT as it shifts out the bore and into this stop you have made. It is better than nothing but do not let if give you a false sense of security.

Best answer is to tap the bore for a threaded plug. not really difficult. next best is to simply put a new expandable plug in place....

You could also braze over the existing plug in the hole.


Mark...

Let me rephrase that ..... "_S_L_I_G_H_T_ piece of mind"
I like the idea of brazing it as it would be faster than the tapping for me.
Time to get the torch!

 

[doctorjj]

I don't want to sound defensive, but as for the points Mark made.

It is true that for some people the plug may leak a small amount without dislodging. My solution will not prevent or stop this.
As for the "if it does dislodge as well, it will leak a LOT as it shifts out of the bore and into this stop", that is not physically possible. On my rig, the plug is already sitting flush and the strip I fashioned is pushing right up against it. In fact, it was underbent just a touch so that when I tightened down the bolt, there is some preload on it. That plug cannot back out AT ALL. Period.
The best answer is to tap the bore, this it true. But we all already knew that.

This is just a simple solution to prevent catastrophic failure. I still think it can give you piece of mind.

 

[alaska60]

I don't want to sound defensive, but as for the points Mark made.

It is true that for some people the plug may leak a small amount without dislodging. My solution will not prevent or stop this.
As for the "if it does dislodge as well, it will leak a LOT as it shifts out of the bore and into this stop", that is not physically possible. On my rig, the plug is already sitting flush and the strip I fashioned is pushing right up against it. In fact, it was underbent just a touch so that when I tightened down the bolt, there is some preload on it. That plug cannot back out AT ALL. Period.
The best answer is to tap the bore, this it true. But we all already knew that.

This is just a simple solution to prevent catastrophic failure. I still think it can give you piece of mind.

And i have piece of mind as I have seen your set up and use it as well. Thanks again for the slice of titanium.
<')))><

 

[Mark W]

I don't want to sound defensive, but as for the points Mark made.

It is true that for some people the plug may leak a small amount without dislodging. My solution will not prevent or stop this.
As for the "if it does dislodge as well, it will leak a LOT as it shifts out of the bore and into this stop", that is not physically possible. On my rig, the plug is already sitting flush and the strip I fashioned is pushing right up against it. In fact, it was underbent just a touch so that when I tightened down the bolt, there is some preload on it. That plug cannot back out AT ALL. Period.
The best answer is to tap the bore, this it true. But we all already knew that.

This is just a simple solution to prevent catastrophic failure. I still think it can give you piece of mind.

Not all the plugs are flush. some are recessed. and... I warned folks against a false sense of confidence... I did not say there was anything wrong with your fix... I would not take that approach but it is cheap and easy,does not hurt anything and it might help some. I stand by that... relax no one attacked your fix.




Mark...