See my profile, I helped my brother-in-law extract a plug he broke off in his truck.
I have had some machine shop experience, I am not a machinist by no means.
I will explain his situation, and you decide if this might work for you.
He was attempting to remove his plugs, while the engine was Hot.
All of them were stubborn, Because the heads were EXPANDED due to the heat (this made the spark plug holes smaller, by thousandths of an inch)
He was fighting one out, when it snapped off, below the Spark Plug SHOULDER.
The entire plug was removed EXCEPT for the THREADED PORTION (body, electrode, and porcelin(sp) was in the Craftsman socket, nothing had fallen into the compression chamber!)
THIS WHOLE DEAL WAS TEXTBOOK PERFECT!
We took another plug, and sawed off the threaded portion, Went to my heavy, half portable, toolbox (which I lugged to his house)
We proceeded to find the most SUITABLE EZ OUT----that would fit INSIDE our "TEST THREADS", from the "DONOR SPARK PLUG" INSURING the point would not go too deep and "Bottom out" on something before it grabbed the threads.
NOTE---an EZ out is a tapered. LEFT-HAND SPIRALED TOOL that you twist ---or--- GENTLY TAP and twist, into a DRILLED OUT BOLT OR, in this case basically "AN ALREADY HOLLOWED OUT BOLT!
The top of these tools (they come in various sizes) HAVE A SQUARE HEAD, the very BEST thing to couple them with is an EXTENSION, and an 8 (not 12) POINT SOCKET! (this is optimum holding power on EZ OUT)
TO CONTINUE THE STORY1st we let the engine go COMPLETLY COLD (so head would shrink, holes get Bigger!)
Since the shoulder was on our Old Removed Plug. (Yippee!) We KNEW there was NO TENSION or BINDING on the threads (thread force pulling against the shoulder, had it broke off in there too)----EXCEPTION---If the plug had been cross-threaed in, to begin with!
In other words, if we could now, put our finger on top of the threaded part in the hole, WE MIGHT COULD SPIN IT OUT EZ! (too deep for that)
I gently tapped the EZ OUT into the hole, A little CCW force on the ratchet, and with VERY little effort, IT CAME RIGHT OUT!
If you lost something of significant size, in the motor, remove the head, get it out!
The man at the parts store will help you with EZ OUT SIZING!
MEDIUM TO MASSIVE TORQUE, Determined by EZ OUT SIZE---AND YOU Will break EZ OUT OFF IN A SECOND (in the head)
Then you are sorta SCREWED, Head must come off, and off to the machine shop, you go!
SO BE SOME-WHAT GENTLE WITH YOUR RATCHET!
LET ME KNOW WHAT YOUR RESULTS ARE!
"WILLY" DOES SEEM TO STARE AT YOU, JUST DON'T TICK HIM OFF!
Saturday, April 3rd, 2010 AT 10:19 PM