frozen oil sending plug

[Mike71Cuda]

Hey guys,
I have a brass plug that I can not get out from the oil sending unit in the back of my hemi. It is a square plug that I have started to round off. Can I put a little heat (bernz-o-matic torch) on it to possibly loosen up? I have tried lubing it up with WD40 etc but that does not work. Any other secrets?

[4Cruizn]

The problem you are going to run into is that the brass is very soft.  I would make other attemps with something other than WD40 and some channel locks.  I've been successful with cutting a groove in the middle of the square ones and then attemp a screwdriver but in the end . . . if nothing else works . . cut off what is left of the rounded off, cut in half brass fitting and drill it out.   

[Mike71Cuda]

Thanks for the comments, but I am concerned with loosing some filings (drillings) into engine if I drill out. Engine has oil which I plan on draining after I get engine broke in (new Hemi). Any objections out there to this?
Thx
Smitty

[Grancoupe]

A machinist showed me how well a hammeer works to break a bolt loose. A couple of smacks is the first thing I would do. If this dosn't work then try some heat. Map gas will give you some more heat than propane. If that dosn't work then I would try drilling out the center. Doing so will take some of the grip form the plug's threads. Lets the plud "shrink" a bit. If it dosen't let go try drilling it out bigger. Eventually you may have to go the other way and try an easy out if the hole needs to be drilled out to big. Remember keep tapping it with a hammer each time. The vibration always helps break the plug loose. I used to do alot of this kind of work. These tricks really work.

[ShelbyDogg]

Here's my trick that I used on a square plug: Take a ratchet  extension, 6" or 12" long, 3/8" or 1/2" drive, whatever fits over that plug "UPSIDE DOWN" and put a big wrench on the exposed end. But as suggested earlier, spray with wd40 then tap a couple of times with a hammer first.    
IF you HAVE TO DRILL, Autozone sell some reverse direction drill bits. as you are drilling, the bit heats up the fitting and walks it out backwards.  Works everytime.  DO NOT USE AN EASY-OUT, IT WILL BREAK OFF IN THE HOLE!

[Chryco Psycho]

lots of heat seems to work for me