Lotus Elan

Oil Gallery Plug Removal

PostPost by: AlfaLofa » Thu Oct 31, 2013 2:26 pm

Any tips on how to shift these stubborn b******s would be most welcome.

Alternatively, I might just leave them be.
Attachments
OilPlugs.jpg and
Steve
'64 S1 Elan (Owned since '73)
'69 Alfa Romeo 1750 Spider Veloce (Owned since '77)
'70 Morris Minor 1000 (Owned since '85)
User avatar
AlfaLofa
Fourth Gear
Fourth Gear
 
Posts: 518
Joined: 19 Aug 2006
Location: Scotland, UK.

PostPost by: pharriso » Thu Oct 31, 2013 3:23 pm

Propane torch on the area around the plug?
Phil Harrison
1972 Elan Sprint 0260K
User avatar
pharriso
Coveted Fifth Gear
Coveted Fifth Gear
 
Posts: 2800
Joined: 15 Sep 2010
Location: Long Island NY, USA

PostPost by: Lotus fan » Thu Oct 31, 2013 4:06 pm

I decided to remove mine....but I wish I hadn't !!

Got 2 of them out easy enough but the 3rd !!!!!

Heat didn't work, managed to 'round' off the hex !!
Drilled it to use a reverse extractor on it........snapped the extractor !!!!

had to drill with 1.5mm drills around the periphery of the plug.....broke 5 drills in the process !!!!!

Can post pics of my toil if you like.

When I finally got the b*****d out the gallery was clear apart from the swarf I had created.

If you don't want frustration leave alone......
Or you might just get lucky !

Ian
User avatar
Lotus fan
Second Gear
Second Gear
 
Posts: 104
Joined: 14 Sep 2003
Location: Wrexham. North Wales.

PostPost by: 512BB » Thu Oct 31, 2013 8:55 pm

I always remove them when I am rebuilding an engine. But if you are not going to strip the whole block down, including removing the jackshaft bearings, leave them in.

Reason. The only way I have found to remove them is to drill them out, with succesive size drills, starting with a 3mm drill, going right through the plug, which will drop some swarf into the gallery. So if you are not going to remove the crank and jackshaft and 3 bearings to thoroughly clean, leave them in.

Why remove the jackshaft bearings? Because the oil feed holes in the bearing do not always line up exactly with the matching holes in the block, leaving a bit of an overhang, which can trap a piece swarf, which will surely emerge when the engine is running.

Leslie
512BB
Fourth Gear
Fourth Gear
 
Posts: 885
Joined: 24 Jan 2008
Location: Cambridgeshire, UK

PostPost by: AlfaLofa » Fri Nov 01, 2013 7:18 am

Ian & Leslie - thanks for your responses.

It just shows I shouldn't believe everything I read :lol:

"undo..... the three oil-gallery plugs using an Allen key"

What a nightmare.

I'll have one more attempt when I receive the appropriate 1/2" drive socket I've ordered - after which I'll give up.

As you say Ian, the gallery is probably ok anyway.
Steve
'64 S1 Elan (Owned since '73)
'69 Alfa Romeo 1750 Spider Veloce (Owned since '77)
'70 Morris Minor 1000 (Owned since '85)
User avatar
AlfaLofa
Fourth Gear
Fourth Gear
 
Posts: 518
Joined: 19 Aug 2006
Location: Scotland, UK.

PostPost by: rgh0 » Fri Nov 01, 2013 7:39 am

I use heat on the surrounding block and a then freeze spray on the plug. 2 or 3 cycles of that normally will get them free. On a few occasions I have ended up rounding out the hex. I have filed up a shaft with a tapered drive fit into a rounded off hex and then worked again on removal using that. In the end I think I have had to drill the plug out on one occasion.

cheers
Rohan
User avatar
rgh0
Coveted Fifth Gear
Coveted Fifth Gear
 
Posts: 7513
Joined: 22 Sep 2003
Location: Melbourne, Australia

PostPost by: 512BB » Fri Nov 01, 2013 8:41 am

Just remembered another method I have used in the past.

The plugs very often protrude up to 3mm from the block face. Carefully cut a slot across the plug, and then with your best tapping screwdriver, on the outside of the plug, tap away. Out she comes.....................sometimes.

They always give it up in the end !

I then run a tap in the threads to clean up, with care, as these are tapered threads. Don't forget to use a thread locker on replacing the new ones, you would not want one of those popping out.

Leslie
512BB
Fourth Gear
Fourth Gear
 
Posts: 885
Joined: 24 Jan 2008
Location: Cambridgeshire, UK

PostPost by: alan » Fri Nov 01, 2013 3:16 pm

i have a block and the rear o?l gallery plug has what appears to be a ballbearing pressed into the hole instead of a threaded plug :?
Alan B
Alan.B
alan
Third Gear
Third Gear
 
Posts: 312
Joined: 29 Jan 2007
Location: France Morbihan

PostPost by: types26/36 » Fri Nov 01, 2013 4:21 pm

alan wrote:i have a block and the rear o?l gallery plug has what appears to be a ballbearing pressed into the hole instead of a threaded plug :? Alan B


That's normal, the earlier engines had a "welsh" type blanking plug (core plug) and the later engines had a ball type plug.
Attachments
ball type blanking plug.JPG and
oil blanking plug.JPG and
Brian
64 S2 Roadster
72 Sprint FHC
User avatar
types26/36
Coveted Fifth Gear
Coveted Fifth Gear
 
Posts: 3655
Joined: 11 Sep 2003
Location: U.K.

PostPost by: alan » Fri Nov 01, 2013 4:36 pm

many thanks Brian, i thought the block had been butchered. I feel much happier now
Alan b
Alan.B
alan
Third Gear
Third Gear
 
Posts: 312
Joined: 29 Jan 2007
Location: France Morbihan

PostPost by: AlfaLofa » Wed Jan 01, 2014 8:43 am

Hi Brian - some questions about the "ball" plug fitted to later engines if I may.

What holds the ball in place?

What's the diameter of the ball?

Is a ball plug fitted to the oil gallery at the front face of the block as well as the rear?
Steve
'64 S1 Elan (Owned since '73)
'69 Alfa Romeo 1750 Spider Veloce (Owned since '77)
'70 Morris Minor 1000 (Owned since '85)
User avatar
AlfaLofa
Fourth Gear
Fourth Gear
 
Posts: 518
Joined: 19 Aug 2006
Location: Scotland, UK.

PostPost by: types26/36 » Wed Jan 01, 2014 9:58 am

AlfaLofa wrote:
What holds the ball in place?

What's the diameter of the ball?

Is a ball plug fitted to the oil gallery at the front face of the block as well as the rear?

Steve,
I have never tried to remove the "ball" so can't answer how it held or it's diameter.
The front of the block has the normal screwed plug.
Have browse over this thread which has some pictures:
lotus-twincam-f39/711m-block-twin-cam-oil-passage-t24032.html
Brian
64 S2 Roadster
72 Sprint FHC
User avatar
types26/36
Coveted Fifth Gear
Coveted Fifth Gear
 
Posts: 3655
Joined: 11 Sep 2003
Location: U.K.

PostPost by: StressCraxx » Wed Jan 01, 2014 7:44 pm

We humble Formula Ford racers scour Craigslist for cheap core engines.
The ball is a press fit in the hole.

Two ways engine builders remove them:
Drill/grind out with carbide or abrasive bits.
Piece of welding rod welded to ball and pull out with a slide hammer.
That part of the galley around the ball can hold debris, so its usually removed.

Regards,
Dan
There is no cure for Lotus, only treatment.
User avatar
StressCraxx
Coveted Fifth Gear
Coveted Fifth Gear
 
Posts: 1033
Joined: 26 Sep 2003
Location: San Francisco Bay Area, California

PostPost by: AlfaLofa » Sun Jul 13, 2014 1:46 pm

What lies behind the plug which screws into the arrowed hole on the right hand side of the engine adjacent to the engine mount??

(Picture courtesy of RD Enterprises)
Attachments
EA.jpg
EA.jpg (71.25 KiB) Viewed 1481 times
Steve
'64 S1 Elan (Owned since '73)
'69 Alfa Romeo 1750 Spider Veloce (Owned since '77)
'70 Morris Minor 1000 (Owned since '85)
User avatar
AlfaLofa
Fourth Gear
Fourth Gear
 
Posts: 518
Joined: 19 Aug 2006
Location: Scotland, UK.

PostPost by: types26/36 » Sun Jul 13, 2014 1:56 pm

I believe that goes into the oil gallery, as I recall I remember seeing some Lotus Cortina's with the take off for the oil gauge from that hole.
Brian
64 S2 Roadster
72 Sprint FHC
User avatar
types26/36
Coveted Fifth Gear
Coveted Fifth Gear
 
Posts: 3655
Joined: 11 Sep 2003
Location: U.K.
Next

Total Online:

Users browsing this forum: 69S4 and 15 guests