Reply to "Oil drain plug catastrophe"

...After reviewing your picture, I can see that NO amount of thread tapping is ever going to seal that opening! In trying to save you the labor involved with completely removing the pan for repair or replacement; there is one more solution I would try: A screwdriver won't properly bend the sheetmetal back into place! Try a Round Steel Bar that will just slide up into the hole, this will give you the needed leverage to 'pull' the collapsed portion down into shape. Being careful NOT to do the opposite, and push the good side IN. Also a 'Slide-Hammer' with a 'Hook' device could work. THEN, have an EXPERT weld a Steel, OR Braze a Brass Pipe-Threaded Adapter into position, and conclude as previously discribed. Don't worry about the inner 'washer' breaking off, if it does, it will just lay in the bottom of the pan and the Oil Pump Intake Screen will prevent it from ever being sucked up into the pump. You can weld with Oxy-Acetalene, or Arc Weld with Mig, Tig or 'Stick'. If you DO arc weld, be sure to completely disconnect the Alternator and Battery. If brazing, you'll want to use the Oxy-Acetalene. If You had this problem in My shop; it would have been fixed in a couple of hours, weeks ago. This is everyones' worst nightmare! Other than that, Pull the Pan!...