Welding diff plug with Gr8 bolt

[fnqcairns]

Will these two metals take? sump plug is rounded inside and this w'end I plan to weld a bolt into it, suspect the nissan plug is made of plasticine , will be using an arc welder.
Asking so I dont accidently make the situation worse .

cheers fnq

[of4x4]

There was a post recently where people had welded a "handle" to the existing plug to remove, and then just replaced with a new plug (or one from a wreckers).

I would assume that a bolt would protrude more, meaning something else to get damaged / broken / stuck. IMO, the diffs are big enough without removing further clearance with a bolt head !

[fnqcairns]

Nah... I want it out, using the jack and a breaker bar it was spreading the head so I gave up before it broke with a bang + I didn't want to butcher the centre. Took it to the pro's they ended up stripping the in-ards round, then wanted to use a hammer and chisel on the rest so I took it back and plan to weld a bolt in, once it's out it goes in the bin.
Last service was by a dealer and both front and back fill plugs are roger-ed in way way too tight.

cheers fnq

[Wendle]

pull out the lower couple of studs holding the diff into the housing and just drain the oil through there..
takes a little while to drain out, but that's what beer is for.

[of4x4]

...plan to weld a bolt in, once it's out it goes in the bin....

Sorry, misunderstood your intentions.

You may have seen this post.
http://www.outerlimits4x4.com/PHP_Modul ... hp?t=66189
Kingy's suggestion of using a nut (at the bottom) sounds the best bet if you can do it.... for the reasons he stated

Good Luck !

[fnqcairns]

That's Ok of4x4, thanks for the link, I am planing on grinding a 16mm bolt down until it fits onto the plug snug , torquing it slightly then welding them both together.

I am a bit of a backyard welder, built boat trailers and stuff but never had the occasion to weld two very different grades of steel, was wondering if the two will take. Last thing I want to do is end up welding the plug to the diff trying to get the Gr8 bolt to take.


Wendle it's the filler plugs that are stuck and now 1 is butchered , with the breaker bar I was able to loosen both drain plugs thankfully, will be doing water crossings on occasion so need it all workable for then. Good tip also it might come in handy one day.

cheers fnq

[lexi]

You could also drill a hole in the new nut to get a plug weld to through to the old nut. A dissimilar metal arc rod may be a help if your not sure of the metal content of the original plug.
Alex

[fnqcairns]

That's a good plug idea lexi thanks, will think on that some more.

cheers fnq