tank plugs

[yowie05]

Hey guys, wondering what you all use for the plugs in the tank that the radiator side plates screw into on older models (04). I've got 1 that is non existent any more and a couple others that are nearly gone. Besides gluing a piece of dowel or similar in there I'm at a loss.
TIA

 

[Zman]

I have not had any luck with glue. I have had some success with melting more plastic into the hole with a soldering iron but if you make a mistake you need a new tank.

I have had the best luck with these threaded inserts. I am not sure if this is the exact size I used or not so buy a few sizes and find the one that is slightly larger than the hole size.

https://www.homedepot.com/p/E-Z-LOK...lush-50-Pack-51-in-length-800610-13/304618041

I think I used a 1/4-20 version that was in stock at home depot. They are too long so you will need to cut down the length to match the hole depth.

You may need to remove the rest of the original plug before you install the insert. I used a bolt and jam nut with the insert as a driver to thread it into the tank hole.

 

[yowie05]

Just what I was thinking. Something similar thanks.

 

[Zman]

I used one of the Dremel bits shaped like this photo to plunge cut out the remaining original plug. Be careful not to go to deep ;-) This is not easy because the bit wants to grab the sides and eat the hole to a larger diameter. It almost makes sense to grid off the side cutting flutes so you only have the plunge / face cutting teeth.

https://www.homedepot.com/p/Dremel-...-Plastic-and-Soft-Metals-2-Pack-115/203672169

 

[Hooligan]

I tried to drill out the plug ...... which didn't go well.

Ended up plugging the hole with 2-part epoxy. Saved the tank but no shroud mount in that location anymore.