Author Topic: Crankshaft sludge plug removal.  (Read 1031 times)

Offline Brandis

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Crankshaft sludge plug removal.
« on: 18.09. 2022 15:28 »
Tried the impact screwdriver.  Rather not use heat.
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Re: Crankshaft sludge plug removal.
« Reply #1 on: 18.09. 2022 16:07 »
If that was my bike and it did not budge...

I'd carefully use an impact drill at low speed (preferably with adjustable Nm, start with the lowest setting).

A bit that was made\filed\prepared to *perfectly* fit the slot (avoid *any and all* slipping ...destruction of the slot) + some quick doses of heat & lube.


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Online Rex

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Re: Crankshaft sludge plug removal.
« Reply #2 on: 18.09. 2022 17:17 »
Drill out the pip before going any further...

Online CheeserBeezer

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Re: Crankshaft sludge plug removal.
« Reply #3 on: 18.09. 2022 17:33 »
I drill through the centre then continue to increase the drill size until there's only a thin ring which I can break inwards with a fine point punch. Never fails.

Offline Brandis

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Re: Crankshaft sludge plug removal.
« Reply #4 on: 18.09. 2022 17:44 »
If I destroy the plug, are new ones available?   I'm a good welder.  I could weld a socket onto the plug and then take that out. 
If they are not available, I could do the clean-out, re-install the plug with the socket still attached and then cut the socket off. 
Does this sound like fantasy land?
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Offline RDfella

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Re: Crankshaft sludge plug removal.
« Reply #5 on: 18.09. 2022 17:49 »
Don't try welding. I did that - the plug still wouldn't shift and it also became so hard from the heat I'd used that it couldn't be drilled, even with tungsten. Clearly wasn't mild steel! Had to grind the thing cleanish and leave it there. Pulled the tube from the other side..
New plugs are readily available (different side to side).
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Re: Crankshaft sludge plug removal.
« Reply #6 on: 18.09. 2022 18:10 »
Drill out the pip before going any further...
Yes.


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Offline Swarfcut

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Re: Crankshaft sludge plug removal.
« Reply #7 on: 18.09. 2022 18:19 »
 Brandis. Those little pips are the crude method of locking the plug, so take a sharp drill and carefully drill them away. The plugs unscrew with a normal lefty loosey thread, and new ones are available or a local machine shop can make them.

 Yours is a small journal crank. it has no central removable tube, just a central through drilling. RD is thinking of the later big journal crank.

 When replacing the plugs, seal with Loctite and screw both in until they are just flush with the crank web, no further. This is to avoid obstructing the oilway that runs from the timing side journal to the first plug cavity. Not so critical on the drive side, just nice to have them match. Also some aftermarket plugs are too thick, so make sure that oilway stays clear. You can add your own pips for belt and braces security, I favour punching metal from the plug into the crank, rather than crank to plug as pictured.

 Plenty about the sludge trap on the Forum.

 Swarfy.

Offline Brandis

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Re: Crankshaft sludge plug removal.
« Reply #8 on: 18.09. 2022 18:51 »
No worries that drilling will unbalance the shaft ?  Or is it just too small an amount of metal to worry about.?
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Online berger

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Re: Crankshaft sludge plug removal.
« Reply #9 on: 18.09. 2022 19:03 »
brandis the way these bikes vibrate at certain speeds drilling or removing any bruising on the web won't make any difference

Offline Swarfcut

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Re: Crankshaft sludge plug removal.
« Reply #10 on: 18.09. 2022 21:19 »
 We're talking a small amount of  sludge mass compared to the mass of all the other rotating and reciprocating stuff. Also if the balance factor changes, within reason the only practical thing of note is that the sweet spot will move in the rev range. Sod's law is that you have a smooth running machine  with the full sludge trap about to spoil your fun....

 Swarfy.

 

Online RichardL

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Re: Crankshaft sludge plug removal.
« Reply #11 on: 19.09. 2022 01:17 »
To me, the slot does not look robust enough to allow for removal of a stubborn plug, even with an impact tool and a perfectly ground tip. If mine, I would follow the tip in the following link about drilling to 5/16" and driving in a 5/16" allen wrench. (Scroll down in link. It HAS worked for me.) Then, if that didn't work, move on to CheezerBeezer's recommendation to drill it out until it's just a thin ring that can be crushed with a punch.

Richard L.

https://cybermotorcycle.com/archives/bsa-super-rocket/endplug.htm

Online RichardL

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Re: Crankshaft sludge plug removal.
« Reply #12 on: 19.09. 2022 05:05 »
...also, I believe there is more to the prep than just drilling out the dimples. The circumference around the plug appears to be deformed and obstructing its removal. This will probably need to be ground or miiled circular and clean with a dremel tool. Of course, with care to remove the least possible material while allowing the plug to be freed.

Richard L.

Offline Swarfcut

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Re: Crankshaft sludge plug removal.
« Reply #13 on: 19.09. 2022 08:14 »
 Richard is certainly correct, and exposing the outer edge of the plug will make things easier. Gentle heat from a hot air gun is also worth adding to the scheme, to soften any locking compound, varnish or jointing used to aid sealing. This is a used crank, so who knows the previous history.

 To state the obvious, first check that the crank runs true and that the journals are not on their final grind or are within stated parameters for wear. It is a lot of work only to find the crank is screwed.

 If the drill down the middle is the eventual method of extraction, a TORX bit hammered in works for me. If all else fails it's drill out as big as you dare and collapse the remains of the thread innwards, as outlined above. New, sharp drills offer the best chance of success, don't struggle with those old blued up blunt buggers!

 That semi-circular slot in the plug is worse than useless. Best original type plugs for removal have a straight slot across the middle, but you still need a straight bladed socket type screwdriver bit, a lot of leverage plus downward pressure on the slot and a bad attitude get them out. For the later big journal crank, replacement hex socket plugs work fine. These are thicker and larger diameter than the small journal plug, so a hex offers more scope for a positive drive if they ever need to be removed at a later date.

 Swarfy.

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Re: Crankshaft sludge plug removal.
« Reply #14 on: 21.09. 2022 12:24 »
G'day Brandis.
I just did them in the A7 crank. I broke 3 impact s/driver bit's till I got a high quality set, A FB Hammer was needed!
Cheers
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