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Welch plugs

O

Old560

Member
This all started out with a leaking exhaust manifold gasket. When I got the manifold off I noticed that the welch plug behind it was leaking the gasket was holding the coolant in. My question is what does someone use to seal the new plug? The last plug I tried to put in leaked I had a terrible time with it. Should I try a permatex aviation form a gasket, or Indian head gasket shellac compound? This is in a forklift and is not easy at all to remove the exhaust and intake manifold very time consuming and frustrating. The last one I did I gave up on and finally put an expandable plug in. Not an option in this case. I will add this one is going to be a pain to pull out it’s only about a 7/8 diameter and the cup is deep.
cvphoto48930.jpg
 
I would drill out the center of the plug with 2 overlapping 5/16 holes. I would then use a hacksaw (jab saw handle on a conventional blade set to pull, not push to cut. Cutting 90% through the cup and not nicking the cast iron. Then tweak up the edge where the cut is and tear the thin edge of the cut to get the tension released, and remove it. I use #2 Permatex on clean surfaces to seal the new plug. Jim
 
And when you get it out, carefully inspect the leading edge of the hole for a burr that can scratch the sealing surface of the new plug as it goes in.

Do use sealer, I like #2 Permatex.

Drive it in by the outer edge, not by something down inside. Hitting inside shrinks the plug. Keep it very straight going in.
 
I usually lightly sand the bore with emery cloth 120-150 grit. I feel the most important part is placing the sealer in the bore ID. That way as it is driven in it rolls up a bead to seal the interface between the bore and plug. The sealers you have mentioned will work fine. I have installed many with RTV with no problems and yes I was careful not to put a big blob of it on there.
 
I just hated working on the forklifts when I was working. No room for anything. My dept. only had one and that was enough. You might be able to get some sheetmetal (large) screws started and pull the old plug out with them and a pry bar.
 
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