If you do not already own any core plug extractors then you will need to make 5 of them. On the left is the largest one and above it is shown located in an exhaust port plug. 3 blank tools were made with the aim of having them double-ended.
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Attempts to remove one of the smaller plugs ended when the high tensile steel pins sheared off. The large plug, shown here, managed about 1/4 turn and it was decided that the risk of wrecking the head exceeded the desire to inspect the waterways - so it was tightened up again. Inspection with a torch and lengths of wire will confirm whether inspection really need to go further - plus the end plates are easier to remove. Remember that the plugs are steel and are screwed into cast aluminium where they have sat, surrounded in water, for the last 7 decades! The following table gives the dimensions and quantities of core plugs in each head. It should be notes that there are two further plug holes: one is used for the temperature sensor and the other is situated in the water jacket. All plugs have 4 socket holes. |
Cylinder head core plug table | All dimensions are given in inches | ||
Outside diameter | Pitch centre diameter | Socket hole diameter | Quantity |
27/32 | 5/16 | 1/8 | 1 |
31/32 | 7/16 | 1/8 | 10 |
35/32 | 7/16 | 7/64 | 9 |
35/32 | 15/32 | 5/32 | 2 |
43/32 | 23/32 | 1/4 | 3 |
25 |