Throw the stupid block off plate away and buy a freeze plug. That is what Mazda uses when they put a BP engine in a font wheel drive car. The hole in the head is machined for a freeze plug to fit.

Bob

A freeze plug is a better solution, but it requires removing the timing belt backing plate, which requires removing the timing belt, which requires removing the cam cover, which requires a new gasket, etc. It's much simpler and cheaper to install a block off plate (as long as it doesn't leak). A freeze plug might be cheap by itself, but if you do it right, it would cost $50 or so to go in and replace stuff (not including the water pump).

Yarp, anytime you open a motor its going to cost you money. But for the op it might be worth it.

Funny thing is that I already knocked out that "welch plug" because my motor was originally an Escort motor. :) I'm not going that route anyway since that would mean having to find a different place to get coolant for the turbo.

yeah, its the same concept of putting a jar lid under hot water to make it expand to make it easyer to take off

We have special rivets in some places on f-16's and a-10 s that require rivets to be kept in a super cold freezer (-50F) so they stay soft, and shrink very slighty. Once they warm up they become brittle but strong as hell and expand to become an interference fit

The BEGI block off plate is made from 0.25" Aluminum. It is plenty thick. If you did not clean the surface of the cast housing prior to using gasket and sealant, that might be your problem. A freeze plug is a great idea, but not if you need to leave your coolant source intact.

Call and let me know if I can help.
Stephanie

Speaking of thermal expansion, we use it in my job as well. There are bushings we install where we heat the bushing up with a heater (to expand it) for installation on the OD of a spindle and we also freeze them in liquid nitrogen (to contract it) for installation on the ID of a hole.

It's already fixed. I opened up the holes on it with a dremel, and put it back on backwards from what I had it like suggested. No leaks.

Cool beans. I actually got something right for once!

I cant beleave that ive never seen this thread,The block offs I make are at least 3/8" thick with a fitting that will feed the turbo.I turn the on the lathe so I have a hard time remembering the exact thickness.Also large diameter washers spread out the clamping force,so it is less likely to leak.
(G)