Broken plug update
06-20-2022, 12:44 PM
#1
Advanced
Thread Starter
Broken plug update
Gents,
I tried one more time this weekend to get the plug shell out and I succeeded! Used a 12.5MM drill bit, greased and drilled out the major portion of the shell save for the threads. Ran a greased 14Mmx1.25 tapered tap cautiously, about 1/2 turn at a time, removed the tap, cleaned the threads,regreased it, rinse repeat. Took about 45 minutes to run the tap through and it took out the remaining steel threads of the plug. Borscope showed clean threads in the cylinder head and no debris in the cylinder. Swabbed the grease out of the plug hole with lacquer thinner, magnet to pull out any metal parts, nothing stuck to it. I spent about 1/2 hour cleaning out the spark plug hole. Threaded new plug in by hand, then torqued to 22 ft. Lbs. per Porsche spec. Started car, some smoke from the penetrant, no noise, strange sounds. Smoke cleared up, car idled, sounded fine. I was extremely lucky and thankful I had a machinist who helped me along the way with his skill. Putting the covers back on, take the car for a drive first time in over 3 months! Knowing what I know now, this kind of job is best left to the pros. I was stubborn and determined to see it through with the help of friends and my wife’s support. All tole, I spent about $300.00 on drills, tools, and machinist labor. Better than thousands of $$$ to pull the engine and head. But that being said, I would NEVER attempt this repair again. If you intend to change plugs yourself, raise the rear of the car to scoot under it, remove the rear plastic cover and use a 6 inch 3/8” extension to get a straight shot at plug #1&4. Not wonky universals, long extensions blah, blah. Many thanks for your interest and support guys. Have a great summer, I know I will!
I tried one more time this weekend to get the plug shell out and I succeeded! Used a 12.5MM drill bit, greased and drilled out the major portion of the shell save for the threads. Ran a greased 14Mmx1.25 tapered tap cautiously, about 1/2 turn at a time, removed the tap, cleaned the threads,regreased it, rinse repeat. Took about 45 minutes to run the tap through and it took out the remaining steel threads of the plug. Borscope showed clean threads in the cylinder head and no debris in the cylinder. Swabbed the grease out of the plug hole with lacquer thinner, magnet to pull out any metal parts, nothing stuck to it. I spent about 1/2 hour cleaning out the spark plug hole. Threaded new plug in by hand, then torqued to 22 ft. Lbs. per Porsche spec. Started car, some smoke from the penetrant, no noise, strange sounds. Smoke cleared up, car idled, sounded fine. I was extremely lucky and thankful I had a machinist who helped me along the way with his skill. Putting the covers back on, take the car for a drive first time in over 3 months! Knowing what I know now, this kind of job is best left to the pros. I was stubborn and determined to see it through with the help of friends and my wife’s support. All tole, I spent about $300.00 on drills, tools, and machinist labor. Better than thousands of $$$ to pull the engine and head. But that being said, I would NEVER attempt this repair again. If you intend to change plugs yourself, raise the rear of the car to scoot under it, remove the rear plastic cover and use a 6 inch 3/8” extension to get a straight shot at plug #1&4. Not wonky universals, long extensions blah, blah. Many thanks for your interest and support guys. Have a great summer, I know I will!
The following 16 users liked this post by Gota996:
cavediver32043 (06-22-2022),
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and 11 others liked this post.
06-20-2022, 01:02 PM
#2
Instructor
Glad to hear of your success! No go for a drive and enjoy it!
06-20-2022, 07:26 PM
#6
Nordschleife Master
A W E S O M E N E W S!!!!!!!! 
Congratulations! And, finally some positive news around here for a change!
Please take some pictures, maybe a video celebration?? ha! Love it!
Congratulations! And, finally some positive news around here for a change! Please take some pictures, maybe a video celebration?? ha! Love it!
The following users liked this post:
SFZ GT3 (06-24-2022)
06-20-2022, 08:19 PM
#7
Porsche Nut
Rennlist Member
Rennlist Member
Excellent news!
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06-21-2022, 07:46 PM
#14
I was following this thread regularly here and on P9. nice update!!
Awesome! That is some careful operating you did. I think I'd be sweating profusely when using the tap.
So just running the tap through pulled out the shell of the plug? No need for an easy out or anything? Nice.
Awesome! That is some careful operating you did. I think I'd be sweating profusely when using the tap.
So just running the tap through pulled out the shell of the plug? No need for an easy out or anything? Nice.
06-21-2022, 10:22 PM
#15
I’ll admit this one had me intrigued. It was beginning to feel like episode after episode of Gilligan’s Island. New gadgets and contraptions but rescue still left to the next episode. I was happy when Gilligan, the Skipper and gang we’re finally rescued. I’m happy for you too. Now I need to start watching some reruns.
The following users liked this post:
Chris MI 987 (06-28-2022)