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Need ideas to remove aft crank plug for C/S prop

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hotwheels

Joined: 01 Jun 2007
Posts: 240

Posted: Mon Apr 27, 2009 11:17 am Post subject: Need ideas to remove aft crank plug for C/S prop

Buying a second hand engine seemed like a good idea at the time. However, the continuing saga of owner sweat equity is starting to get old!



My O540 engine originally was configured for a fixed pitch prop. To convert over to a C/S prop, there are two plugs that need to be removed from the crank. The forward one was removed before the engine was mounted. However, the aft plug is still present. It has an offset 9/32" hole pierced into the steel plug that's about 7" behind the front of the crank. The plug is the press in type, not threaded. The governor oil tube is about 1.5" forward of the plug (just to make it interesting).



Several folks have pointed me to using a dent puller slide hammer to remove the plug. No joy here so far. I can get to the hole, but the hook attachment gets hung up on the oil tube. Trying to thread a rod into the hole didn't work as 5/16" is too large and 1/4" is too small... The cheap dent pullers use a mandrel w/ screw, but it would seem difficult to get it into steel.



A helpful guy at the local Advanced Auto Parts store suggested using a bearing puller. However, the issue is that the hole is quite small and there's no guarantee that spending $150 for a puller that has a good assortment of attachments will get me any further. The auto parts place does rent bearing pullers, but they are too large.



Splitting the case and tapping out the plug is not an attractive option.



Have others gone through this process? If so, what worked? 



Thanks in advance for replies!



Jay

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cehoffman(at)bellsouth.ne
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Posted: Mon Apr 27, 2009 12:35 pm Post subject: Need ideas to remove aft crank plug for C/S prop

My O-540 also required different counterweights on the crank to match the 

C/S prop.



Cal

---

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hotwheels

Joined: 01 Jun 2007
Posts: 240

Posted: Mon Apr 27, 2009 12:48 pm Post subject: Re: Need ideas to remove aft crank plug for C/S prop

Thanks. That to-do was done a while back. 



Jay



do not archive



 	  cehoffman(at)bellsouth.ne wrote: 	
		  My O-540 also required different counterweights on the crank to match the 

C/S prop.



Cal

---

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msausen

Joined: 25 Oct 2007
Posts: 559
Location: Appleton, WI USA

Posted: Mon Apr 27, 2009 2:36 pm Post subject: Need ideas to remove aft crank plug for C/S prop

Have you tried contacting an engine builder like Barrett for advice?



Michael



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hotwheels

Joined: 01 Jun 2007
Posts: 240

Posted: Tue Apr 28, 2009 9:08 am Post subject: Re: Need ideas to remove aft crank plug for C/S prop

Update... Several good ideas showed up on my inbox, but I guess no one wanted to go out on a limb and state them in public. 



1) Weld a screw on the end of a rod. Thread screw either into existing hole or make a new one. Tap against the bent rod end to remove plug.



   - I like this one and give it a good chance for success... So long as the weld holds up. Wish the slide hammer I bought had this option, but learning how to weld might be fun.



2) Coat oversize screw with Permatex or Pro-Seal, screw into existing hole and leave it in place.



   - An A&P suggested this and on the surface it doesn't appear to be too likely to result in a Darwin Award nomination. However, it sorta puts the "E" in Experimental and my wife might not like it either. Think I'll pass on this on.



3) Disassemble engine and tap plug out from the backsize of the crank. 



   - This dog doesn't hunt as I don't believe the crank has an aft opening.

Thanks for the responses. 



Regards,

Jay

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hotwheels

Joined: 01 Jun 2007
Posts: 240

Posted: Wed May 13, 2009 9:01 am Post subject: Re: Need ideas to remove aft crank plug for C/S prop

Drilled a new hole in the old plug. Threaded in a self tapping bolt and popped it out using an el-cheapo slide hammer from Harbor Freight. Unscrewed the bolt using a channel lock and fished the plug out with a magnet. The new plug was inserted using a magnet and seated by tapping on two brass rods. 



A shopvac, magnet and oily rag got the metal shavings out. It took maybe half and hour once all the right tools were in hand. All in all, there are lots of other harder things to do on the project... once it's in the rear view mirror.



Cheers,

Jay

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