Oil change, stipped hex, help!

Went to change the oil the other day and with my mind elsewhere I tightened the hell out of my hex bolt with the expected results of completely stripping it. Now it's nice and smooth. Thinking I was a smarty I stuck in some JB Weld and my bit and waited. Once that had set I turned and got a sprinkling of JB Weld and my bit back. poop

I am searching for a solution that does not involve drilling.
The vice grips are great if you have something to grip. I have be trying to grip the 1mm lip at the base with no luck as the plug sits into the pan.

Any ideas?

Alligator socket...Or bore the bolt and re thread and purchase a new one. Just don't have your mind else where and drive your car with your oil plug in.

[edit on 9-2-2007 by tsloan]

how large is this sump plug [ diameter ] ?

solutions which come to mind are :

1 - weld a nut to the face of the sump plug - filling in the centre of the nut with a MIG welder

2 - select an TORX socket , the closest over size to the hex socket you were using - and hammer it in then attempt to use that to remove it

3 - use a large punch to hammer the face of the sump plug - to deform the round lip - then hammer the hex key into the hole [ see picture ]

NB - with 2 and 3 - the hammering action also helps lossen the plug [ just like an impact wrench or driver ]

PS - dependant on how its constructed - do not hammer it too hard

you can fracture an aluminium cassting , deform a steel pressing or damage the thread / captive nut



hope this helps - and i hope you learned your lesson