There's an aftermarket plug available...Greaseworks, I think.  Stainless
steel or solid gold (a joke), given the cost of it.   Anyway, that might
help your leak, depending on what is actually going on with your drain
hole.....It may have become distorted by your welding repair....Takes a
very skilled welder to work aluminum without deformation..

On Sat, Dec 22, 2012 at 1:29 AM, Scott Daniel - Turbovans <
scottdaniel@turbovans.com> wrote:

> I have converted that drain plug to a convconventional 'washer seals
> under the hex head'regular drain plug.
> A jetta/rabbit drain plug is the same thread..
> and has a hex head ....put some good sealing washer under the hex head..
> Make the matingsurface on the pan as smooth and flat as you can.
>
> that might work.
> Scott
> turbovans.com
>
>
>
> On 12/21/2012 10:47 PM, Dana Mueller wrote:
>
>> Howdy Kind VW Fanatics!
>>
>> I have a 1982 VW Diesel 1.6 - stock everything.
>>
>> You may recall I had an oil pan that was munged at the drain.  Cracked
>> horribly.  Got that fixed, filled and tig welded.
>>
>> Issue:  Drain plug leaks like a mofo.  I followed the torque
>> recommendation
>> to tighten the plug and it still dripped out like nuts where the tapered
>> end meets the oil pan.
>>
>> Question:  What do you guys recommend to gasket that dang taper?  Some
>> black gasket material into the female recess between oil changes?  Any
>> thoughts, opinions, pointers, etc welcome.
>>
>> As always I appreciate your help immensely.
>>
>> -dm
>>
>>