Stripped plug socket - longish

Discussion in 'UK Motorcycles' started by David Ellis, Oct 24, 2003.

  1. David Ellis

    David Ellis Guest

    On Monday morning I set off to work, whilst gently passing a couple of
    cars about a mile from home, there was a knock from the engine area
    and the bike sounded like the header pipes had fallen off. I limped
    back home.

    Back at home it was obvious the noise was coming from the top of the
    engine. Investigation revealed thet the spark plug on no. 1 cyl had
    blown out stripping the thread. Fucking Great[1].

    Having used thread inserts in the past with great success I decided to
    repair the sod myself. Also, I wanted to make absolutely sure no swarf
    dropped into the engine.

    The problem on the blade is accessibility, even with the camshaft
    cover off the the thread is around 4 to 5 inches down the hole and
    there is a frame cross member above just to make things awkward.
    Raking through my toolbox, I found a 1/4 inch socketed tool that I
    could modify. The Recoil kit I bought had a tap with 2 cutters on. The
    bottom is a standard 10mm plug size and the upper one is for the
    thread insert, this makes aligning much easier.

    I plastered the tap in grease and cut down about 3mm deep before
    removing and and cleaning the tap of swarf collected by the grease. I
    repeated this until I was through to the bottom.

    With the aid of a mirror and torch I could see that nothing had
    dropped onto the piston top. Result.

    The tool provided was not long enough to screw in the insert and so I
    was going to make my own tool but longer. Then I had a brainwave. I
    used the the blown out plug with the thread turned off in a lathe. I
    sawed a slot down the end of the plug to accept the tang on the
    insert. The idea being that the plug electrode that was also slotted
    could be nipped to hold the tang and prevent it falling into the
    engine when it was broken off after insertion. The plug also has a
    stepped, non threaded part which seats down the hole, so this method
    would make sure the insert was put in far enough.

    I screwed in the insert until the plug seated and then yanked it out
    to break off the tang. Unfortunately the tang fell into the engine.
    A small magnet [2] taped to piece of copper wire soon extracted the
    foreign body [3].

    Job finished, the new plug now tightens down nicely.

    Well chuffed I am.

    A bit boring I know but it might help someone one day.

    [1] Obviously I hadn't tightened the thing enough, although it's
    probably 6 months since I last had them out.
    [2] Well actually, a larger 12mm dia magnet smashed to bits with a
    [3] I'd checked before that the stainless insert was actually magnetic
    just in case.
    David Ellis, Oct 24, 2003
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  2. David Ellis

    SteveH Guest

    Heh.... I used the patented smashed up big magnet tied to a garden cane
    when I dropped my only set of keys to the shite old Golf down a drain
    outside the house. Took about 15 mins of prodding, but I eventually
    pulled the keys out :)
    SteveH, Oct 24, 2003
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  3. David Ellis

    Jeremy Guest

    .... is there a happy ending to this story?
    Jeremy, Oct 24, 2003
  4. David Ellis

    Rob Guest

    Maybe you (or previous owner) tightened them too much?
    Rob, Oct 25, 2003
  5. David Ellis

    David Ellis Guest

    In the 3rd Millenium, on Sat, 25 Oct 2003 15:06:32 +0100, Rob
    David Ellis, Oct 25, 2003
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