removiing broken spark plug

[Porkchop]

Does anyone have any tips for removing a broken spark plug? The engine is still in the truck and it is an aluminum head. There is about a quarter inch of the plug sticking out of the head, but the hex is broken off. It is frozen in there. I have tried heating with a torch (I can't get it too hot because the head is aluminum), and I have tried tapping it out with a screwdriver or and hammer. I really don't want to have to pull the head. I have heard that there is a tool you can use to tap a spark plug hole and it will catch the shavings so they don't fall in. Maybe I could use it to get the plug out. Does anyone know anything about that?
So does anyone have any ideas?
Thanks a lot

[kwmech]

You will probably have to remove the cyl head to do the job correctly and not damage the head itself.








P.S. anti-seize is your friend in the future

[jhow66]

1st thing to do is bring that piston to top dead center on firing stroke. (this way when you are finished you can take a shop vac and suck out any debris) Then try turning the plug back in to loosen it up. Then use an eze-out to try to remove it. If this fails find a metal jig saw blade the is small enough to fit into the plug hole. Use vise grips to hold blade and saw the plug remains into. Get heli-core kit and resize hole . Do the shop vac bit and you are home free. (NOTICE--the above advice carries no warrenty implyed or otherwise)

[Shane]

Dip your tap in axle/bearing grease before chasing the threads. The grease that is in-between the flutes of the tap will catch and hold the chips.

Old machinist trick for tapping "blind" holes.