Stupid pipe plug

In trying to remove the oil galley pipe plugs from the outside of the engine block, I ran into a major problem. The one with the hole in it that the throttle return spring goes through broke. The head sheared off. I figured I would grind it flat, drill it, and use an ez-out. Well, the ez-out sheared off inside. This thing is really stuck and now I can't drill anymore because the hardened steel of the ez-out is stronger than the drill bits. Any ideas?

On separate but related topic, anybody want to buy a Jeep?

 

Weld a nut to it and grab that. Heat from welding also helps loosen up the bond between the parts.


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Well, I managed to make it worse. I tried grinding it past end of the ez-out. Now it is ground flat with the engine block and I still can't drill through it -- I think I broke at least 7 expensive DeWalt drill bits. I like the idea of welding a nut on it but now that it is flat with the engine block, I'm not sure that's possible. Maybe I'll just haul the block down to a machine shop and have them get all the oil galley plugs out.

 

I had a broken bolt in the differential housing. I messed around for quite a while trying to get the easy out removed and didn't get anywhere. I ended up going to the machine shop and it was $35 and they also cleaned the threads.

 

Yeah I came to the conclusion last night that I will just take the block to the machine shop and ask them to get it out for me. I'll also have them remove the remaining plugs and clean the oil galley for me. Whatever they charge, it will be worth it.

 

Dropped the block off at the machine shop this morning. The guy didn't give me a warm fuzzy, he had his doubts about getting it out. I hope I'm not having to shop for a new block.

 

I can't believe very strongly in a machine shop that doesn't have a variety of answers to this common problem.

 

Cool that would be awesome to build. But with the luck I've been having lately, I would probably burn the garage down.