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Oil Plugs - Simple Question

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SuperA-Tx

02-09-2007 10:57:48




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I been wondering something so Im going to go ahead and ask.

You have the oil plugs on the gear box and on the final drives that are about 1 1/2 inches wide. In the center is the square 1/2 opening where you put the end of the socket to tighten or loosen it. At the bottom of that square hole on the plugs you see on each corner a tab kind of thing sticking out with jagged edges and they meet in the center forming a diamond shape. Then theres a little space between them and the actual bottom of the plug. Was there a reason it was built like that?

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GA Dave

02-09-2007 19:23:19




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 Re: Oil Plugs - Simple Question in reply to SuperA-Tx, 02-09-2007 10:57:48  
Thanks for clearing this subject up. I think I'll scrap my square bits now, HAW HAW! David. PS I always wondered how they did that.



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Wardner

02-09-2007 11:18:55




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 Re: Oil Plugs - Simple Question in reply to SuperA-Tx, 02-09-2007 10:57:48  
It seems you have a steel plug, made from round bar, as opposed to a cast plug. The square hole was broached square after drilling. The pattern you see are the chips that were not torn out during the broaching process. I suppose a cast plug could also be broached for a better tolerance. It is likely, however, that the chips would separate from the plug and fall out. If the plug was forged steel, it is not likely to have been broached. The only machining would be the pipe thread. Each process is dependent on OEM costs and available equipment.

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SDE

02-09-2007 14:02:48




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 Re: Oil Plugs - Simple Question in reply to Wardner, 02-09-2007 11:18:55  
Are you sure about them being broached? I thought after the round hole was made that they were stamped out with a square punch. I use a broach at work and I don't see that, as the type of application that a broach is use for. Obviously I don't everything about broaching, but I have never seen one used for a blind hole. We use a shaper for those. I really would like to know how they do it if you are correct.
SDE

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Wardner

02-09-2007 14:48:18




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 Re: Oil Plugs - Simple Question in reply to SDE, 02-09-2007 14:02:48  
We are getting into semantics here. I'm using the verb "broach" and your are focused on the noun form. Yes, without a doubt, the broach used for the 1/2" square blind hole would look like a punch.

I have taken the liberty to copy a paragraph from vwbroaching.com. Put "www" in front of that for more info.

"Blind broaching refers to the machining of a piece part in which the broaching tool is unable to, because of the design of the part, pass completely through or completely past the part. The broach therefore must cut into a ‘blind’ cavity of some sort. Designing the tooling for, and executing the process of blind broaching is very much an art that is reserved for the most experienced of craftsmen. V W Broaching Service is pleased to perform all types of blind broaching operations, from the most simple ‘punching’ of a shape into a round hole, to more complex forms involving multiple passes using several tools. An example of a blind broaching operation would be the cutting of an internal hexagon into a headless setscrew."

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SDE

02-10-2007 06:52:52




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 Re: Oil Plugs - Simple Question in reply to Wardner, 02-09-2007 14:48:18  
Thank you for the info. I really was curious about it.



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SuperA-Tx

02-09-2007 11:33:45




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 Re: Oil Plugs - Simple Question in reply to Wardner, 02-09-2007 11:18:55  
Thanks. Now I can stop wondering about that. lol

El Toro, no they arent magnetized.



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Janicholson

02-09-2007 11:22:38




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 Re: Oil Plugs - Simple Question in reply to Wardner, 02-09-2007 11:18:55  
Perfect answer. JimN



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Wardner

02-09-2007 11:47:00




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 Re: Oil Plugs - Simple Question in reply to Janicholson, 02-09-2007 11:22:38  
Thanks, maybe Kim could paste a gold star on it. It would be nice to show to my mother.



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El Toro

02-09-2007 11:18:42




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 Re: Oil Plugs - Simple Question in reply to SuperA-Tx, 02-09-2007 10:57:48  
Are they magnets? Touch them with a screwdriver
and see if they are attracted. Hal



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