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Old 05-19-2017, 10:59 AM   #1
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Default How To Remove Drain Plug From SeaRay

Hello,

I own a 1994 SeaRay 240 Overnighter and I have a question about removing the drain plug. While attempting to remove the drain plug from my boat last fall while in storage, the edges of the drain plug became so stripped that I was unable to remove it. To prevent the boat from filing with water during the winter, I decided to drill a hole in the middle of the drain plug for the water to escape.

Now that I'm getting my boat ready for the summer, I have a question about the best way to remove the drain plug:

a) option 1 appears to be drill out as much of the drain plug as possible and then gently hammer out the remaining plug (it is a soft material, so I assume it is brass?). Then I can maybe use a 'tap' to redo or repair the threads in the event that I damaged any of the threads while drilling or removing.

b) option 2, if you look at the attached picture (which is similar to my boat), I don't know what will happen if I try to remove the 3 screws and remove the whole assembly? Is this the easiest method, or will removing this create a bunch of work, e.g. will I then need to get in the engine compartment to properly repair / remove everything?

I guess I just worried about what will happen if I try option b vs just going with option 1 which seems to be pretty straight forward.

Thanks in advance!
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Old 05-19-2017, 11:08 AM   #2
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THe drain assembly is 5200 in. That's tough to remove. I would first try to remove the plug it self. can you cut a slit in it and use a large screw driver? Maybe tap the hole you drilled and screw a bolt in and trough to the other side. attach a but to that bolt and try to unscrew the drain plug that way. A pic of the drilled plug would help.
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Old 05-19-2017, 11:23 AM   #3
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THe who assembly is 5200 in. That's tough to remove. I would first try to remove the plug it self. can you cut a slit in it and use a large screw driver? Maybe tap the hole you drilled and screw a bolt in and trough to the other side. attach a but to that bolt and try to unscrew the drain plug that way. A pic of the drilled plug would help.
Thanks for the quick reply... actually, before I drilled a hole in the plug, I tried a cut a slit in the plug, but that didn't work since the plug must have been really over-tightened. Then I drilled the hole in the drain plug a little larger and tried using a bolt extractor (it has reverse threads), but because I was having to put so much pressure and leverage on my socket set, I figured I might damage the assembly.

Unfortunately I won't have a picture for about another week.
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Old 05-19-2017, 11:35 AM   #4
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hmmm. can you start soaking with pb blaster? I would try to avoid removing the outer assembly until you have exhausted every option removing the drain plug first. I don't know if you could try heating the outer ring a little. when the outer ring is hot you could hold an air can upside down and spray the drain plug and shrink it a little and then give it a shot. Good luck.
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Old 05-19-2017, 11:38 AM   #5
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just take those 3 screws out, go get a new plug, clean it all real good make sure there is no anti-fouling on the mounting surfaces and install the new one fully bedded with 3M 4200. .
if the screws were loose and wont tighten rotate the plug and drill new holes with a 1/8" drill bit and install with new 8x3/4" screws with the whole thing bedded well in 3M 4200
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Old 05-19-2017, 11:41 AM   #6
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Originally Posted by seatec View Post
hmmm. can you start soaking with pb blaster? I would try to avoid removing the outer assembly until you have exhausted every option removing the drain plug first. I don't know if you could try heating the outer ring a little. when the outer ring is hot you could hold an air can upside down and spray the drain plug and shrink it a little and then give it a shot. Good luck.
Actually I tried using AreoKroil (similar to PB) and it didn't help - I didn't use heat yet, I but want to avoid that for the time being.
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Old 05-19-2017, 11:46 AM   #7
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Originally Posted by Raybo Marine NY View Post
just take those 3 screws out, go get a new plug, clean it all real good make sure there is no anti-fouling on the mounting surfaces and install the new one fully bedded with 3M 4200. .
if the screws were loose and wont tighten rotate the plug and drill new holes with a 1/8" drill bit and install with new 8x3/4" screws with the whole thing bedded well in 3M 4200
Thanks for this... I just wasn't sure if I take the 3 screws out, that once I do that, I need to get into the engine compartment, etc?

Install what with 3M 4200? You indicated to get a new plug, but also a brand new assembly as well?
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Old 05-19-2017, 12:47 PM   #8
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They are inexpensive. Replace the whole mess. The threads are likely damaged on both sides. Fix it once.
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Old 05-19-2017, 12:53 PM   #9
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On mine, the factory used a through bolt for one of the mounting screws, so the garboard drain plug could be electrically bonded on the interior to the boat's bonding system.

They put a nut to hold the assembly, then a nylock nut to hold the wire lug.

Don't use 5200 when replacing that part. The best / only usage for 5200 is on someone else's boat. Use 4200 or an equivalent sealant to retain the assembly. I've never needed sealant on the plug's pipe threads.
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Old 05-20-2017, 04:58 AM   #10
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The best / only usage for 5200 is on someone else's boat.
Best advice I've seen - it should be made a "sticky" at the top of the page.
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Old 05-20-2017, 05:01 AM   #11
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Use a easy out first to see if it can grab it?
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Old 05-20-2017, 05:12 AM   #12
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Quote:
Originally Posted by gil_happy View Post
Hello,

I own a 1994 SeaRay 240 Overnighter and I have a question about removing the drain plug. While attempting to remove the drain plug from my boat last fall while in storage, the edges of the drain plug became so stripped that I was unable to remove it. To prevent the boat from filing with water during the winter, I decided to drill a hole in the middle of the drain plug for the water to escape.

Now that I'm getting my boat ready for the summer, I have a question about the best way to remove the drain plug:

a) option 1 appears to be drill out as much of the drain plug as possible and then gently hammer out the remaining plug (it is a soft material, so I assume it is brass?). Then I can maybe use a 'tap' to redo or repair the threads in the event that I damaged any of the threads while drilling or removing.

b) option 2, if you look at the attached picture (which is similar to my boat), I don't know what will happen if I try to remove the 3 screws and remove the whole assembly? Is this the easiest method, or will removing this create a bunch of work, e.g. will I then need to get in the engine compartment to properly repair / remove everything?

I guess I just worried about what will happen if I try option b vs just going with option 1 which seems to be pretty straight forward.

Thanks in advance!
Remove the 3 screws. Use a thin putty knife to pry/cut the sealant from the boat. Clean area, re-seal and replace with new plug. Put a little neve seize on the new plug and don't tighten it to much. Good luck.
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Old 05-20-2017, 07:26 AM   #13
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Originally Posted by TsunamiTsling View Post
Remove the 3 screws. Use a thin putty knife to pry/cut the sealant from the boat. Clean area, re-seal and replace with new plug. Put a little neve seize on the new plug and don't tighten it to much. Good luck.
Great, thanks so much!
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Old 05-20-2017, 08:25 AM   #14
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i always use Teflon tape when i reinstall in the beginning of season
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Old 05-20-2017, 09:10 AM   #15
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I have coated that plug with OMC triple guard grease every year and have never had a problem getting it out. Make sure the threads in the housing are not cross threaded.
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Old 05-20-2017, 04:32 PM   #16
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Good vice grips.
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Old 05-20-2017, 05:57 PM   #17
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Quote:
Originally Posted by Raybo Marine NY View Post
just take those 3 screws out, go get a new plug, clean it all real good make sure there is no anti-fouling on the mounting surfaces and install the new one fully bedded with 3M 4200. .
if the screws were loose and wont tighten rotate the plug and drill new holes with a 1/8" drill bit and install with new 8x3/4" screws with the whole thing bedded well in 3M 4200

This
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Old 05-20-2017, 07:39 PM   #18
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If Aerokroil didn't help it must really be in there. You'll probably have to remove the entire thing.

However, the Hail Mary to get a plug out is a small steel pipe wrench with a cheater pipe slipped over it. That pipe wrench will bite like a rottweiler and something is coming loose with that combination. But if you've drilled the head off the plug that won't work.
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Old 05-20-2017, 08:14 PM   #19
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Hope it's not too late...get an easy out screw extractor of the appropriate size. It screws into the hole you drilled....lefty-tighty. It screws in to your plug tighter as you loosen the drain plug using a tap handle or adjustable wrench. When you get it out, get a couple of huge stainless cotter pins, drill a hole crossways in your new plugs, and push the cotter pins in to form a handle with which to tighen the plug without over tightening. Leave the cotter pin in the plugs (one in the hole plus a spare of course). Good luck!
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Old 05-21-2017, 02:50 AM   #20
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Simple, easy and correct way is to use a plumber's 1/2" easy out. Drill hole big enough to get the point of it in and have at it with a big wrench.
Works every time in brass plugs

Cutting it out is last resort, because chances are 9 out 10 that the plug is Cast Brass as opposed to machined from stock
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