Damn.... I cant believe you are having that many problems!! I am still trying to get a day off this weekend to come up to Pheonix and check out the car..

Rat

 

Man take that bitch to Jiffy Lube and let them deal with it.

 

Not to be demeaning, but there is. Ever since I got laid off from the tech industry I have been working as a mechanic. Only reason I say this is because the Snap On guy comes by every week(YES!!!!! SWEEET!!!!!) Snap on has a special set of sockets to remove rounded off bolts, they work excellent. Granted, these are most likely out of reach and out of the question for this situation and the home mechanic. Copandengr, A 6 point is always the obvious choice to remove a bolt, but sometimes on bolts that have been rounded off to an extent, you can no longer get a 6 point socket on or it is just not effective at all.

 

A rubber mallet works wonders, and I have yet to muck things up with one.
hanman

 

use a pair of Curved jaw Vice Grips....just use full force. get another drain plug!

 

I noticed recently on my 86 NA that the oil pan drain is shaped a little strange. Instead of being a threaded hole with a square edge for the bolt to seal to, there is a taper, or reverse chamfer. This taper is shaped like the hole was countersunk. The oil drain plug had a crushable aluminum washer on it that had roughly conformed to the taper. It leaked some, so I did away with this and used a copper washer from the parts store.

Perhaps you have a similar situation and the thing is really locked down because of the taper. From what you describe the problem may require putting the vehicle on a lift so more effective methods can be used.

I have a lot of experience with EZ-Outs. They are ineffective trying to back out a bolt that is siezed into the threads.

As a last resort, the suggestion to weld a nut on the plug head is a good one. The heat from welding will cause the bolt to expand, but it can't because of the relatively cold threaded hole. This means the plug will actually be compressed some. When it cools off it will be microscopically smaller than it was and should come out easily.

 

if you need access to a torch go buy one at home depot their like 5-10 dollars it's a little hand held one