How do you remove those #$%^ "tamper-proof" plugs??

[DrCharles]

I'm rebuilding that Holley 4180 I mentioned in another thread. It was really fun getting the body-to-baseplate gasket off. CRC Gasket Remover isn't all that it's cracked up to be...

Now I need to remove the two pressed tamper-proof plugs so I can get to the idle screws. The Holley kit instructions say to center-punch them (no problem), then drill a 3/32 hole through, then an easy-out. But that hardened steel just laughs at any drill I have, and my carbide burrs don't have sharp teeth on the end.

What do you use to get them out?

[Justa1time]

Is this Skunkworks Dr. Charles?

[GTO Geoff]

In my opinion, easy-outs are misnamed. Should be called never-outs. The concept forces the bolt/screw even harder. Drill & tap for a small screw.

[DrCharles]

I've always said that Easy-Out is two lies in one (it's not easy and it won't come out)
The problem I'm having is drilling it. These plugs are apparently hardened to make it even more difficult to remove!
Thinking of tacking a 1/16" welding rod to it, and then just pulling on the rod...

No, I'm not associated with Skunkworks. I've had a few jobs in my 40+ years in the workforce but not that one

[DrCharles]

I got them out, but not without a struggle. Tamper-proof, my ass

First I tried to get a 1/16" welding rod to stick (usually the opposite of what I'm trying to do!), but ended up gouging a small pit in the plug instead. It had gotten hot enough that the temper was gone and I could drill into it with a #36 (picked that size in case I had to tap for a screw thread) deep enough for an easy-out.

For once, an easy-out actually worked. Turns out they aren't welch plugs but a piece of solid steel rod about 1/4" deep with shallow hardening.

Now I'm going to cut a small screwdriver slot in the heads of the needles with a Dremel cutoff wheel so I don't have to use an Allen wrench and hope it doesn't strip out. It's next to impossible to turn an Allen wrench with the carb on the manifold, anyway. Then it all goes back together.