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I'm installing a Vortex EFI engine into my touring wagon.

Problem being that the Vortex had the Oil pressure gauge, but no warning light.
I need to give the gauge back & want to install the light.

Problem being that the screw in bung where the Light Sensor goes (it's in a different hole of different size) made of aluminium has seized in there & now I've bascially rounded off 2 corners of it trying to get it out.

Wondering if anyone has any ideas.

Heat it up maybe (I have a small hand held blow torch)

I did the same to mine, and from memory, i got a file and made it fit the next size spanner down, then bashed on the open ender and was very careful with it and i eventually got it.

Maybe see if you can get a 6 sided socked (as opposed to the normal 12 side) on there, it will give you more surface area

I supose it's more like my brass one same deal. Dissimilar metals corroding together but with mine I ended up drilling it (not all the way through) smaller to bigger bits with the intension of using an easy out but just drilling it out was enough to get it moving so then it was only a matter of using vice grips then an open Ender to unscrew it.

But what's the go with an excel as a rally car apart from getting in the smaller classes.

Bit worried about drilling it because then metal could end up in the oil galleries etc.

I may try to get an adaptor & stick the sensor into the oil pressure gauge hole instead. At least that's already out.

Excel: there's a one make series designed to keep cost down(ish) to get people into rallying with limits on modifications, weight, etc.
Surprisingly, they're quite tough (once the front end has been reinforced), plus they're damn cheap & easy to get parts for.

I believe something similar happened with my Vortex EA82T , I vaguely remember Jacko saying he had to weld a bolt to something to get it out of the oil pump .

With a plug you'd probably want to shrink it by cooling it with that freeze spray bearing places sell - in a pressure pack can .

Cheers A .

Or you could swap the oil pump out for one off a non turbo... It would be a good time to replace the seals and rotors too.

Just a thought!

Cheers

Bennie