So,
Ultra-gray
or
JB Weld
??
I can agree with either.
They both have pro's and con's.
I have no plans to do much, if anything, to it anytime soon.
Thanks again for all the input.

 

Put the ultra-gray around the new freeze plug and install. Then cover the entire surface with a layer of JB Weld.

 

if you if you really want it fixed right the thing to do would be weld up the id of the casting plug bore and then bore it out to the OEM size and it will be as good as new. By the way to one of the other posters, those are not actually freeze plugs they're casting plugs and they are not designed to pop out if the Block freezes, that's just a lucky side effect sometimes. Having Frozen a block once I can tell you that they do not save the block always, I froze a 3.8 L Buick V6 once and it cracked the jacket in the lifter gallery.

I would assume any repair cost would be borne by the shop that screwed it up.

 

So you think that surface can be tig welded?
How well does cast aluminum tig weld?

 

Ha! Yeah, that's what I was thinking.

 

 

Yep, the might is what concerns me.
I don't want it failing on me...or the next guy, if I sell or trade it.
I like the welded caps idea, but am unsure how well it would stick to cast. It would also cost alot more than I want to put into it.

 

 

Good enough for Jay Leno and his fine collection of cars

 

They've been called freeze plugs since the beginning of time, and do pop out...l've seen it several times in my career. And yes, sometimes they don't. But, l guess we can change the name today...but good luck at the parts store when you ask for casting plugs...you are going to get a stone cold stare from the parts guy at the counter...lol.

​​​​​​​ Brian.