[Diastole]

Charlie, not enough sticking out for a pipe wrench.
Gene, started applying Kroll penetrating oil yesterday. Would you prefer PB Blaster?
Group, if I am going to weld a bolt, I do not want to screw up the two sides sitting proud. If I going to weld a nut, it does not matter. So vice-grips option is still pending. The nut likely has not been removed in 19 years in talking to the widow wife. Husband complained about that after they bought it 2005.

I like the welding idea yall propose. I'm a savy novice welder. I went to the mill and bought a piece of 1/2" square bar. It matches the 1/2" socket designed for the plug. I can weld that to the raised edges and use a 1/2" wrench. Once the penetrating oil soaks in.

I ordered 1/16" welding rods with flux since I am out of gas for the MIG welder. That should give me plenty of penetration. I do not have a TIG peddle.

Bob, thanks for the IM. I agree with your diagnosis. The problem is the damaged plug has a 1/2" recess for a socket wrench. That leaves very little metal of the plug to accept the torque. The new plugs have a 3/8" recess and that leaves more metal on the edge. See photos. I will replace the drain plug with a magnetic one and thicker walls, thanks, nkaminar.

Plan to try on Wednesday (four days hence). I will update you'all.

Thanks,

Diastole in the Smoky Mountains