Technical  Stripped spark plug hole thread...

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Technical  Stripped spark plug hole thread...

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Expanding taps were patented in 1870

If you don't know they exist, you don't know to look for, ask for them, I guess the back tap became popular with the rise of aluminium heads 1990s

Looking at the prices £5 upwards, Sealy ones are around £15
I've come across expanding reamers and used them, but never thought about an expanding tap. I first saw this type of expanding tap some years ago, which, of course, is intended very specifically to clean plug threads and overcome the swarf problem. However an expanding tap for use in the normal way? Never knew they existed. Every day's a school day as they say.
 
They should go in dry if you are going to torque them up using a torque wrench

Oiled will over tighten them and risks damage

They are coated, no need to oil read link in post 5 should explain everything

Start them by hand they are at an angle



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although even with an ali head , it can feel dry and stiff..as you say too much is no good
 
They can be re threaded without removing the head.


Looking at that video again, that tap enlarges the hole to allow for the insert so it seems to me that a fair amount of swarf must drop into the cylinder. Does that insert take any make of spark plug ? Is there a standard thread used on all spark plugs ?
 
Looking at that video again, that tap enlarges the hole to allow for the insert so it seems to me that a fair amount of swarf must drop into the cylinder. Does that insert take any make of spark plug ? Is there a standard thread used on all spark plugs ?
Nope. Different diameter for different plug sizes and different lengths of insert too. Right kit needs to be bought.

Some swarf in the bores is pretty inevitable. But plenty of grease on the tap and only taking a small "bite" before backing out, cleaning the tap, regreasing and taking another bit helps a lot. Piston at TDC compression stroke before you start and blow out with airline when finished.

On many engines access makes this a variabley difficult job. And don't forget all the plugs may not be aligned identically. For instance the FIRE engines have two plugs with axis leaning slightly to the N/S and two leaning to the O/S.
 
Looking at that video again, that tap enlarges the hole to allow for the insert so it seems to me that a fair amount of swarf must drop into the cylinder.
Already answered

Don't overly worry about the metal swarf

Start the engine with the plug out, blows the majority out

The rest will either pass the exhaust valve or get burnt off

There not big enough or hard enough to cause any damage

The head doesn't burn because it large and soaked the heat away

Small aluminium pieces burn



If you follow the advise in the link I post and you are careful,.the plugs should come out and go back in with any damage, unless they were installed incorrectly in the first place

Three years is nothing
 
A low cost endoscope camera will allow you to look into the cylinder for debris. (Lidl has one right now). Get a rubber tube slim enough to go down the spark plug hole and gaffa tape it to your vacuum cleaner. Check before and after to be sure there's no debris.
good idea
 
Nope. Different diameter for different plug sizes and different lengths of insert too. Right kit needs to be bought.

Some swarf in the bores is pretty inevitable. But plenty of grease on the tap and only taking a small "bite" before backing out, cleaning the tap, regreasing and taking another bit helps a lot. Piston at TDC compression stroke before you start and blow out with airline when finished.

On many engines access makes this a variabley difficult job. And don't forget all the plugs may not be aligned identically. For instance the FIRE engines have two plugs with axis leaning slightly to the N/S and two leaning to the O/S.
hi..coming back to this I still have not changed the plugs and in particular No1 which once it's out ..might not accept a new plug. This is a kit I bought on E Bay. Seen anything like it ? Thats the NGK s/ plug. Panda 1.2 ltr
 

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hi..coming back to this I still have not changed the plugs and in particular No1 which once it's out ..might not accept a new plug. This is a kit I bought on E Bay. Seen anything like it ? Thats the NGK s/ plug. Panda 1.2 ltr
Sorry velvet but impossible to say yeah or nae from just a picture like this.
Those certainly look like inserts and that is a taper tap which presumably will cut the hole out larger to accept the insert. That sort of repair kit is common enough. However it needs to be exactly the correct thread and length for your application. What info was given on the packaging?
For example, I have a Helicoil repair kit for 14mm spark plugs, it says exactly that on the box. Inside it contains the threading and installing tools and a selection of several lengths inserts for different reach plugs. This wouldn't work for our Panda which has 12mm plugs. - See what I mean? More info needed.

Edit. If it were me I'd take that plug out and carefully examine the thread in the hole. It's not impossible that all it needs is a plug tap, or even a Slotted plug, run down the threads to clean them up to a usable condition. By "slotted" plug I mean a plug with the ceramic smashed out of it and the slots cut in the threads to make it into a thread chaser. I have a picture of mine somewhere on my laptop which I'll try to find and post on here for you.
 
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There you go, found the picture of my home made spug thread cleaner. It's made from an old 14mm plug, slotted and welded to a length of tube with an old bolt in the top so it can be worked using a socket or spanner

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Hope that is useful?

Edit it is so long because it was originally made to tackle a plug hole on a 504 Peugeot and they had deeply recessed plugs.
 
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Probably will not be needed

But

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Is not a good option, don't use it, it looks like it will cause more damage than good

What should be sharp cutting edges are rounded, the tops looks ragged

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A proper tool is made of HSS with a proper lead in and has a proper cutting edge
 
Probably will not be needed

But

View attachment 488847

Is not a good option, don't use it, it looks like it will cause more damage than good

What should be sharp cutting edges are rounded, the tops looks ragged

View attachment 488848

A proper tool is made of HSS with a proper lead in and has a proper cutting edge
Oh well done that man. I just magnified the image and I agree. Very poor quality tool.
 
If it's just the first few threads that are damaged

You are better using a back tap

You drop the tap inside the plug hole,.so it's behind the damaged threads

Expand it into the good threads

And wind it out so it follows the known good threads

Again not a tool to cheap out on, something like a bluepoint is around £30


You may get lucky with a cheap china clone from eBay or Amazon but it's a gamble

Good explanation



And the reality in real life, is rarely going to be that easy



If a plug is torqued down correctly, and you are careful taking it out and back in

I have never known there ever to be a problem just changing the plugs
 
If it's just the first few threads that are damaged

You are better using a back tap

You drop the tap inside the plug hole,.so it's behind the damaged threads

Expand it into the good threads

And wind it out so it follows the known good threads

Again not a tool to cheap out on, something like a bluepoint is around £30


You may get lucky with a cheap china clone from eBay or Amazon but it's a gamble

Good explanation



And the reality in real life, is rarely going to be that easy



If a plug is torqued down correctly, and you are careful taking it out and back in

I have never known there ever to be a problem just changing the plugs

Came across these a few years ago. Oh boy, I want one! Can't really justify one just because I want it though - and you'd want to cover at least 14mm and 12mm so need two minimum.
 
Came across these a few years ago. Oh boy, I want one! Can't really justify one just because I want it though - and you'd want to cover at least 14mm and 12mm so need two minimum.
I've just looked at the £10 Vs £30 versions

One has nice smooth threads the other rough

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Looks like you get what you pay for, ground Vs cut

Whether it make much real world difference i dont know
 
I've just looked at the £10 Vs £30 versions

One has nice smooth threads the other rough

View attachment 488899View attachment 488900

Looks like you get what you pay for, ground Vs cut

Whether it make much real world difference i dont know
T'wood be interesting to know. Many threads are rolled these days. Don't know if a segmented assembly like this would lend itself to rolling though?
 
If you get any sort of swarf into the engine, do at least make as much effort as possible to remove as much of it as possible, blow it out with compressed air, use a vacuum cleaner etc.

Aluminium requires a high temperature to burn which is not going to happen instantaneously when you start the car. So pieces could be bouncing around for quite a while before they burn off, also aluminium oxide won’t burn so if it does “burn” any by products will still remain in the cylinders.

Also very tiny particles and fragments could end up passed the piston rings of a cold engine and end up circulating around in the oil.

Arguably the amount of damage that some tiny fragments of alloy could do is going to be very small but it’s still not wise to adopt the approach of just leaving it, and assume everything will be fine.

Also if you are cutting new threads then there is bound to be dirt and other contaminants that end up in the cylinders so best to just try and keep everything as clean as possible.
 
I think, as long as you take every reasonable precaution - so liberally greasing the tap and only cutting maybe a turn to a turn and a half before winding it out, cleaning down the flutes and applying new grease, maybe also blowing out the cylinder with a long nose blowgun (one which gets right into the cylinder so the air blows stuff out rather than a short reach which will be inclined to blow stuff into the cylinder - make sure the valves are closed before blowing so the bits come back out the plug 'ole not onward past the valves!) assuming you have the luxury of a supply of compressed air of course - then I don't think you should worry too much. Although it would be wrong to say I've done hundreds of thread reclamations like this - from just running a tap down the hole to correct a minor bit of damage to installing a helicoil insert - I have done a fair few number of them over the years. In fact I've done more inserts on small engines, Briggs and Stratton, Tecumseh, and others as the side valve jobbies have very short reach plugs which are easily stripped if over tightened - the combination of short reach plug and "ham fisted" horticultural worker/gardener is almost guaranteed to give you a regular supply of engines with these problems! I can honestly say I'm not aware of any of the repairs I've done later resulting in an engine with bore damage - and a lot of the horticultural ones will be engines I saw regularly over a year or two for servicing. I'd argue you're more likely to end up with this sort of damage because you don't properly blow out the road grit from around the plug before removing it at service time. If you don't know what I'm saying here then you should always slacken the plug by half to one turn, to loosen up the packed down grit, before thoroughly cleaning around the base of the plug and cylinder head - compressed air works best for me - It's sometimes surprising the blizzard of grit which can get in your eyes if you're not careful. If you don't do this then some of it is bound to drop into the plug hole as you remove the plug and almost certainly get down between the piston and cylinder wall. Many modern engines will have individual "coil on" ignition coils and because of the way the coil often has a rubber seal/grommet between it and the "tunnel" in the head, are much less prone to this problem, but I still tend to give then a blow out just in case - doesn't take any time at all, so why not? also, with a lot of engines now being twin OHC with the plugs in the middle between the cam covers, you can get oil leaking down around the plugs if there's a gasket leak. Quick "squirt with the air gun quickly reveals this and stops the oil dumping into the cylinder if you haven't noticed and just whip the plug out.

So I think my advice is, exercise good practice, don't rush the job and don't worry - it's almost certainly going to be Ok. For the inexperienced a far bigger problem is going to be inserting the tap without cross threading it! Due to poor access or weirdly angled plugs. The FIRE engine, for instance, has two plugs angled slightly one way and the other two angled the other way. I believe this alone can cause a newcomer to the engine to cross thread the plugs/plugs.
 
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