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(Post Link) post #1 of 16 Old 13-03-10 Thread Starter
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broke the spark plug off!

Hi all. Some of you may be aware that I purchased a spider a couple of weeks ago to add to my collectfion! well it came with no service history so in the process of cambelt change etc. Got to the plugs. One was very stiff. Tried to be ever so careful by going back and forward but it broke off. Bugger.

So i'm going to drill out the centre and use these extractors. Anyone else got a better suggestion????

Laser Screw Extractor 6pc from Halfords Price 9.99
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Have you got a picture of the remains?
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(Post Link) post #3 of 16 Old 13-03-10 Thread Starter
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No but I can explain what is left in th head. Its in a ts engine and its the smaller plug of the two in number two cylinder. the plug was about half way out at most and sheared off right at the top of the threaded part that goes in the head. Sheared off flat
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Hi Joss, sorry to hear about you latest adventure with the Spider. If i where you i would PM Mitch166, Smaky or iainfm as those guys know the answer to most mechanical conundrums.

After a quick google found this although it looks like you already know.
"Over the years I have had to remove the threaded portion of a broken off plug with the head on and off and it really depends on how badly it is seized in the head. I got most out by heating the left over piece of plug with a acetylene torch, then inserting a large "EZ" out that has been left in a freezer. The heat tends to break the rust loose but expands the plug, the cold EZ out tends to cool and contract the piece of plug while the head is still warm. I have however had to drill out some and a few that required an insert as the threads were damaged in the process. I don't know of any way to tell you that will always work in all cases and I don't believe there is one other than to remove the head and jig the head up in an end mill and cut it out which is costly and time consuming.

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The centre of the plug should be possible to drill out (or similar), then extract the body. The bore will need meticulous hoovering out afterwards though. I've heard my MOT guys talk about the crunching noises made by an engine as it mashes up crap left in a bore. Not nice!

Might be better to take it to a specialist engine shop for extraction. Might work out cheaper in the long-run.

Smaky's the expert though, not me!
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I wouldn't ............. Get one of them jammed in there or snapped off and you are buggered.............. The big problem with them is that the way they work has the net result of expanding the thing you want to get out making it tighter in the hole .................. Take it to a good machine shop and get it "Spark Eroded" you might even save the thread in the head.

Cheers to All
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(Post Link) post #7 of 16 Old 14-03-10 Thread Starter
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Ok so an update on broken plug missery. Drilled most of the plug out but couldn't fold the rest over. Going to get a long 9mm drill bit tomorrow to open it out further. tap ordered and on its way!!! I hate t-sparks LOL
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Personally i would of considered a head off job, to save to bore. Now you have swarf on top of the piston and i doubt your going to get it all out...
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I know what you mean but my straw selotaped onto hoover end has worked a treaty so far so confident most is out. If the bore gets scored i'll just have to bite the built and get the honing kit out!
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These small plugs on the TS are a real pain. I had no.8 snap last year, the thread casing stayed in the bore but everything else came out. Was able to remove casing, but only because the casing wasn't seized.

Only tips in future are don't overtighten, and keep the threads lubricated just a little bit with copper slip. But the plug design (being so small) is open to problems and, with all the other issues regarding this engine, makes it all a real pain. To run one of these Fiat hybrid engines you've got to be slightly mad...........

Hope you get it sorted Joss.
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Lots of plusgas in the recess a few days before plug change helps minimise risk.. I know it won;t help you now, but may help others in the future.
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(Post Link) post #12 of 16 Old 18-03-10 Thread Starter
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No worries. Well if I get home tonight and its still light i'll be running the 9mm drill down it and then the 10x1 tap before cleaning the bore out. Fingers crossed it'll be running by the weekend. then off to the MOT!
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Don't be too concerned over any small granules of swarf,(bigger ones are less acceptable) as when she fires up they will quickly burn away. Test steel and aluminium or whatever filings with a gas torch for example? Whoosh and they are gone? Firework material. :

Drilled out a stripped plug thread in of my past Jags, fitted the helicoil, no problems with the filings/swarf.
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spark erosion all the way
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(Post Link) post #15 of 16 Old 18-03-10 Thread Starter
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Yeah the old man said get as much out as possible but not to worry too much (he's a mechanic) Said it will cough and misfire and prob sound like a bag of $hite until it clears itself, but should do in the end.
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(Post Link) post #16 of 16 Old 20-03-10 Thread Starter
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Final update on plug. drilled out. tapped and plug in. Sucked out rubbish from chamber and started. Let just say that it didn't sound pretty. Bang, bang, bang, misfire, quiet, bang, bang, bang and clear. vroom vroom. I think shes cleared! the ts lives to fight another day!!!
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