It is already ground flat. Starting to leak oil now. No luck though. Oil pan already ordered.

 

The thought had crossed my mind. I can weld ok, but wasn't sure how to weld a nut now that it is ground flat. How would I keep the nut held there to weld? Also, I am a bit concerned about a fire hazard in that area.

I am still willing to bet that I'd break the weld sooner than I'd be able to get this lose.

Either way, oil pan on the way. I'd rather avoid changing the pan but the pan was cheap. Welders always seem to stick it to me.

 

Uhmmm, I wasn't the one who did this. I have changed oil hundreds of times on scores of cars and never had this issue.

 

Have you ordered a Fumoto yet?

 

No, I already have a magnetic drain plug that I intend to use.

 

May I suggest a method that would not require changing out the pan? Just grind off that protruding piece, then get a very sharp drill bit, say 3/8 inch in dia. Use a center punch so as to be in the center of the bad drain plug. Coat your drill bit flukes with wheel bearing grease so as to catch the chips and drill a hole in the bad drain plug. Then use an "EasyOut" and back out the drain plug. You may not even need to drill all the way through the drain plug to get a sufficient "bite" with the "EasyOut". Certainly worth a try vs. dropping and replacing the oil pan.

 

^^^^ This is a good idea if you do not go too big with the drilled hole, and the easy out. If you do, hammering the easy out into the hole can actually make the bolt/plug/screw/etc expand and grip even tighter on the threads.

 

Thanks on the Easy-Out idea, but I ground off that piece already then tried Easy Outs earlier on in the thread starting with Easy Out sizes 1, then 2, then 3, then 4. :(

However, you are the first to give me an idea on how to go completely through that drain plug potentially. At some point, it started taking all year to go through the plug and the drill bit said get lost.

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Bummer! Did the drill bit snap off in the hole? If not, get a better drill and use a variable speed drill. Take it slowly. Heat build-up is the enemy. Keep the drill flutes covered in grease and clean off chips periodically until you break through. The flow of oil should wash out any possible remaining chips. We're with you in spirit!

 

Thanks for being there. The bit didn't snap off in the hole. Good Dewalt variable drill is being used. Hard to get leverage down there actually. I might try a different bit if time allows...while I await the new oil pan.