In a message dated 13/10/2004 1:50:46 PM Eastern Daylight Time,
LISTSERV@GERRY.VANAGON.COM writes:

NAPA and  other FLAPS have oversized drain plugs.
Carry yours in and get the next  larger size.
Many times you can get good aluminum or copper crush washers  to go with
them.

Stan and all, this does not work very well from my  experience.  I used to do
this and have seen many waterboxer engines that  have had this type drain
plug.  They will always leak.  You will never  get it to seal perfectly.  The
reason I have concluded is that when you  oversize the drain plug hole the
sealing area for the crush gasket has been  reduced.  In every case where this was
occurring I installed a  Helicoil or Time-Sert threaded insert with the OEM
drain plug and new  copper crush gasket.  Gasket must be changed every time the
oil drain plug  is removed.  There will be no leaking as long as the sealing
surface on the  block is not damaged.

Cheers,

Frank  Condelli
Almonte, Ontario, Canada
_BusFusion_ (http://members.aol.com/BusFusion/bfhome.htm)  a VW Camper
camping event, Almonte, ON, June 09 ~ 12, 2005
'87 Westy, '90 Carat &  Lionel Trains
Member: _Vanagon List_ (http://www.vanagon.com/) , _LiMBO_
(http://www.bcn.net/~limbo/) , _IWCCC_ (http://www.westfalia.qc.ca/)  & _CCVWC_
(http://www.ccvwc.ca/)
Vanagon/Vanagon Westfalia Service in  the Ottawa Valley
_STEBRO/Vanagon Stainless Steel  Mufflers_
(http://members.aol.com/Fkc43/stebro.htm)
_Frank Condelli &  Associates_ (http://members.aol.com/Fkc43/busindex.html)
or  http://frankcondelli.com