Subject: Re: [Shop-talk] Drilling through a spark plug to make a christmas ornament?

From: Benjamin Zwissler via Shop-talk <[email-masked]>
Date: Fri, 14 Dec 2018 08:37:41 -0500

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I'd say if the spark plug was constructed properly you'll have a real bear
of a time getting the conductor out.  Everything is installed through the
top with the inner electrode subassembled into the white ceramic insulator
first. The assembled white ceramic insulator is then placed in the steel
housing with some sealing material and then mechanically retained with a
crimp.

This is a good overview:
https://www.denso.com/global/en/products-and-services/automotive-service-parts-and-accessories/plug/basic/structure/

The center copper electrode is retained in the ceramic insulator with a
ceramic powder that is solidified with pressure and heat.  They're not
supposed to come out even after hundreds of thousands of combustion cycles
exposing them to high heat and pressure.  The most common failure mode is
the steel housing is damaged from over-torquing and then the whole ceramic
center assembly blows out during combustion making a nice dent in the
hood.  Knock can cause damage to the ceramic and the electrode but rarely
does that cause anything other than misfire.

Drilling out the center electrode would be my only recommendation, but I
suspect that won't be easy either.  I the bit gets out of the center and
contacts the ceramic its likely to get dull rapidly and its a long narrow
channel that would require really tight alignment.

Ben....

On Fri, Dec 14, 2018 at 8:01 AM Jim Franklin via Shop-talk <
[email-masked]> wrote:

> While lying awake at 0-dark:30 I had an idea of turning old spark plugs
> into ornaments by inserting blinking lights in them. I thought for sure it
> would have been done but I can't find anything out there in Internet land.
> Is it possible to pull out the center electrode with hand tools and a vise?
>
> thanks,
> jim
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-- 
Ben Zwissler
[email-masked]
Columbus, IN

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<div dir=3D"ltr"><div dir=3D"ltr">I&#39;d say if the spark plug was constru=
cted properly you&#39;ll have a real bear of a time getting the conductor o=
ut.=C2=A0 Everything is installed through the top with the inner electrode =
subassembled into the white ceramic insulator first. The assembled white ce=
ramic insulator is then placed in the steel housing with some sealing mater=
ial and then mechanically retained with a crimp.=C2=A0=C2=A0<div><br></div>=
<div>This is a good overview:=C2=A0=C2=A0<a href=3D"https://www.denso.com/g=
lobal/en/products-and-services/automotive-service-parts-and-accessories/plu=
g/basic/structure/">https://www.denso.com/global/en/products-and-services/a=
utomotive-service-parts-and-accessories/plug/basic/structure/</a><br><div><=
br></div><div>The center copper electrode is retained in the ceramic insula=
tor with a ceramic powder that is solidified with pressure and heat.=C2=A0 =
They&#39;re not supposed to come out even after hundreds of thousands of co=
mbustion cycles exposing them to high heat and pressure.=C2=A0 The most com=
mon failure mode is the steel housing is damaged from over-torquing and the=
n the whole ceramic center assembly blows out during combustion making a ni=
ce dent in the hood.=C2=A0 Knock can cause damage to the ceramic and the el=
ectrode but rarely does that cause anything other than misfire.</div><div><=
br></div><div>Drilling out the center electrode would be my only recommenda=
tion, but I suspect that won&#39;t be easy either.=C2=A0 I the bit gets out=
 of the center and contacts the ceramic its likely to get dull rapidly and =
its a long narrow channel that would require really tight alignment.</div><=
/div><div><br></div><div>Ben....</div></div></div><br><div class=3D"gmail_q=
uote"><div dir=3D"ltr">On Fri, Dec 14, 2018 at 8:01 AM Jim Franklin via Sho=
p-talk &lt;<a href=3D"mailto:[email-masked]">[email-masked]=
.net</a>&gt; wrote:<br></div><blockquote class=3D"gmail_quote" style=3D"mar=
gin:0 0 0 .8ex;border-left:1px #ccc solid;padding-left:1ex">While lying awa=
ke at 0-dark:30 I had an idea of turning old spark plugs into ornaments by =
inserting blinking lights in them. I thought for sure it would have been do=
ne but I can&#39;t find anything out there in Internet land. Is it possible=
 to pull out the center electrode with hand tools and a vise?<br>
<br>
thanks,<br>
jim<br>
_______________________________________________<br>
<br>
<a href=3D"mailto:[email-masked]" target=3D"_blank">Shop-talk@aut=
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alk/[email-masked]" rel=3D"noreferrer" target=3D"_blank">http://autox=
.team.net/mailman/options/shop-talk/[email-masked]</a><br>
<br>
</blockquote></div><br clear=3D"all"><div><br></div>-- <br><div dir=3D"ltr"=
 class=3D"gmail_signature" data-smartmail=3D"gmail_signature"><div dir=3D"l=
tr"><div><div>Ben Zwissler<br></div><a href=3D"mailto:[email-masked]"=
 target=3D"_blank">[email-masked]</a><br></div>Columbus, IN<br></div>=
</div>

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From: John Innis via Shop-talk <[email-masked]>
Date: Fri, 14 Dec 2018 07:42:31 -0600

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I have done this, but only in the context of removing a broken plug from
the head.  In my case the hex head broke off of the metal body.  I had to
get the insulator out to remove the broken plug.  That was easier than I
expected, but the insulator was broken in the process and what was left
didn't look much like a spark plug.  I think if I was going to do this I
would remove the insulator and then make a fake replacement insulator to
hold the light.  could be made from a dowel painter white, or a bit of soda
straw, or if you know someone who has a 3d printer they could make a really
nice bulb holder to fit in there.  I've got a few old plugs lying around.
I might try this just for fun this weekend...

On Fri, Dec 14, 2018 at 7:05 AM Jim Franklin via Shop-talk <
[email-masked]> wrote:

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<div dir=3D"ltr">I have done this, but only in the context of removing a br=
oken plug from the head.=C2=A0 In my case the hex head broke off of the met=
al body.=C2=A0 I had to get the insulator out to remove the broken plug.=C2=
=A0 That was easier than I expected, but the insulator was broken in the pr=
ocess and what was left didn&#39;t look much like a spark plug.=C2=A0 I thi=
nk if I was going to do this I would remove the insulator and then make a f=
ake replacement insulator to hold the light.=C2=A0 could be made from a dow=
el painter white, or a bit of soda straw, or if you know someone who has a =
3d printer they could make a really nice bulb holder to fit in there.=C2=A0=
 I&#39;ve got a few old plugs lying around.=C2=A0 I might try this just for=
 fun this weekend...<br></div><br><div class=3D"gmail_quote"><div dir=3D"lt=
r">On Fri, Dec 14, 2018 at 7:05 AM Jim Franklin via Shop-talk &lt;<a href=
=3D"mailto:[email-masked]">[email-masked]</a>&gt; wrote=
:<br></div><blockquote class=3D"gmail_quote" style=3D"margin:0px 0px 0px 0.=
8ex;border-left:1px solid rgb(204,204,204);padding-left:1ex">While lying aw=
ake at 0-dark:30 I had an idea of turning old spark plugs into ornaments by=
 inserting blinking lights in them. I thought for sure it would have been d=
one but I can&#39;t find anything out there in Internet land. Is it possibl=
e to pull out the center electrode with hand tools and a vise?<br>
<br>
thanks,<br>
jim<br>
_______________________________________________<br>
<br>
<a href=3D"mailto:[email-masked]" target=3D"_blank">Shop-talk@aut=
ox.team.net</a><br>
et=3D"_blank">http://www.team.net/donate.html</a><br>
Archive: <a href=3D"http://www.team.net/pipermail/shop-talk" rel=3D"norefer=
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alk/[email-masked]" rel=3D"noreferrer" target=3D"_blank">http://autox.te=
am.net/mailman/options/shop-talk/[email-masked]</a><br>
<br>
</blockquote></div><br clear=3D"all"><br>-- <br><div dir=3D"ltr" class=3D"g=
mail_signature">=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=
=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D<br>=3D Never offend people with =
style when you=C2=A0=C2=A0 =3D<br>=3D can offend with substance --- Sam Bro=
wn=C2=A0 =3D<br>=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=
=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D=3D</div>

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From: Donald H Locker via Shop-talk <[email-masked]>
Date: Fri, 14 Dec 2018 08:58:42 -0500

I wouldn't say it can't be done, but I'm sure I couldn't do it. 
Interesting idea.

Donald.
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On 2018-12-14 7:48 a.m., Jim Franklin via Shop-talk wrote:
> While lying awake at 0-dark:30 I had an idea of turning old spark plugs into ornaments by inserting blinking lights in them. I thought for sure it would have been done but I can't find anything out there in Internet land. Is it possible to pull out the center electrode with hand tools and a vise?
> 
> thanks,
> jim
> Unsubscribe/Manage: http://autox.team.net/mailman/options/shop-talk/[email-masked]
> 

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From: Jimmie Mayfield via Shop-talk <[email-masked]>
Date: Fri, 14 Dec 2018 09:17:34 -0500

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I wonder if you use an EDM to drill out the electrode?

On 12/14/18 8:37 AM, Benjamin Zwissler via Shop-talk wrote:
>
> Drilling out the center electrode would be my only recommendation, but 
> I suspect that won't be easy either. I the bit gets out of the center 
> and contacts the ceramic its likely to get dull rapidly and its a long 
> narrow channel that would require really tight alignment.
>
> Ben....
>
> On Fri, Dec 14, 2018 at 8:01 AM Jim Franklin via Shop-talk 
>
>     While lying awake at 0-dark:30 I had an idea of turning old spark
>     plugs into ornaments by inserting blinking lights in them. I
>     thought for sure it would have been done but I can't find anything
>     out there in Internet land. Is it possible to pull out the center
>     electrode with hand tools and a vise?
>
>     thanks,
>     jim
> Unsubscribe/Manage: http://autox.team.net/mailman/options/shop-talk/[email-masked]
>

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    <div class="moz-cite-prefix">I wonder if you use an EDM to drill out
      the electrode?<br>
    </div>
    <div class="moz-cite-prefix"><br>
    </div>
    <div class="moz-cite-prefix">On 12/14/18 8:37 AM, Benjamin Zwissler
      via Shop-talk wrote:<br>
    </div>
    <blockquote type="cite"
cite="mid:[email-masked]">
      <meta http-equiv="content-type" content="text/html; charset=UTF-8">
      <div dir="ltr">
        <div dir="ltr">
          <div><br>
            <div>Drilling out the center electrode would be my only
              recommendation, but I suspect that won't be easy either. 
              I the bit gets out of the center and contacts the ceramic
              its likely to get dull rapidly and its a long narrow
              channel that would require really tight alignment.</div>
          </div>
          <div><br>
          </div>
          <div>Ben....</div>
        </div>
      </div>
      <br>
      <div class="gmail_quote">
        <div dir="ltr">On Fri, Dec 14, 2018 at 8:01 AM Jim Franklin via
          Shop-talk &lt;<a href="mailto:[email-masked]"
            moz-do-not-send="true">[email-masked]</a>&gt;
          wrote:<br>
        </div>
        <blockquote class="gmail_quote" style="margin:0 0 0
          .8ex;border-left:1px #ccc solid;padding-left:1ex">While lying
          awake at 0-dark:30 I had an idea of turning old spark plugs
          into ornaments by inserting blinking lights in them. I thought
          for sure it would have been done but I can't find anything out
          there in Internet land. Is it possible to pull out the center
          electrode with hand tools and a vise?<br>
          <br>
          thanks,<br>
          jim<br>
          _______________________________________________<br>
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            moz-do-not-send="true">[email-masked]</a><br>
          Donate: <a href="http://www.team.net/donate.html"
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          Archive: <a href="http://www.team.net/pipermail/shop-talk"
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          <br>
        </blockquote>
      </div>
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      <div><br>
      </div>
      -- <br>
      <div dir="ltr" class="gmail_signature"
        data-smartmail="gmail_signature">
        <div dir="ltr">
          <div>
            <div>Ben Zwissler<br>
            </div>
            <a href="mailto:[email-masked]" target="_blank"
              moz-do-not-send="true">[email-masked]</a><br>
          </div>
          Columbus, IN<br>
        </div>
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      <br>
      <fieldset class="mimeAttachmentHeader"></fieldset>
      <pre class="moz-quote-pre" wrap="">_______________________________________________

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From: Jeff Scarbrough via Shop-talk <[email-masked]>
Date: Fri, 14 Dec 2018 11:30:03 -0500

Why reinvent the wheel?  Just get a battery, a spare distributor, and
some long plug wires.  Rig a motor to turn the distributor, and hang
the plugs in the tree.  Don't forget to water it!

Jeff Scarbrough
Flammable Acres, Ga.
On Fri, Dec 14, 2018 at 8:04 AM Jim Franklin via Shop-talk
<[email-masked]> wrote:
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From: Jim Franklin via Shop-talk <[email-masked]>
Date: Fri, 14 Dec 2018 12:05:48 -0500

> On Dec 14, 2018, at 11:30 AM, Jeff Scarbrough <[email-masked]> wrote:
> 
> Flammable Acres, 

:-D

I think I'll abandon this quest. It was a thought for an ex I'm still friends with. I might have done this while I was courting her and trying to impress. Now, not so much. :-)

jim

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From: Steven Trovato via Shop-talk <[email-masked]>
Date: Fri, 14 Dec 2018 12:19:13 -0500

I have been waiting for someone to say how great it must be to have 
all your cars and  projects complete so you can spend time thinking 
up stuff like this!  Sorry, I really don't have anything productive 
to add, so an obnoxious comment is the best I can come  up with right now. :-)

-Steve T.

At 07:48 AM 12/14/2018, Jim Franklin via Shop-talk wrote:
>plugs into ornaments by inserting blinking lights in them. I thought 
>for sure it would have been done but I can't find anything out there 
>in Internet land. Is it possible to pull out the center electrode 
>with hand tools and a vise?
>
>thanks,
>jim

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From: Eric Russell via Shop-talk <[email-masked]>
Date: Fri, 14 Dec 2018 12:54:18 -0500

Or a magneto. Add a hand crank and put the grandkids to work.

Eric Russell
Mebane, NC

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From: Richard George via Shop-talk <[email-masked]>
Date: Fri, 14 Dec 2018 12:19:31 -0800

Hmmm....  along those lines I suppose you could also just solder an led 
between the center electrode and the side electrode and hook up a DC 
power supply - you'd need what, ~50V for a sparkplug with a 5K ohm 
resistance...  Trouble is I don' t know if the resistor in the sparkplug 
could dissipate that ~1/2 Watt of power...

:-P

Maybe giving up is a good idea

Best,

rkg

(Richard George)

On 12/14/2018 9:05 AM, Jim Franklin via Shop-talk wrote:
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From: Jeff Scarbrough via Shop-talk <[email-masked]>
Date: Fri, 14 Dec 2018 16:46:35 -0500

> Or a magneto. Add a hand crank and put the grandkids to work.

See how ideas improve when you collaborate?
_______________________________________________

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From: Jim Franklin via Shop-talk <[email-masked]>
Date: Fri, 14 Dec 2018 18:04:33 -0500

Love this idea, and I might have some non-resistors laying around.

We'll see if I can get the garage cleaned and lit in time, but this is rapidly becoming a 2019 project...

jim

> On Dec 14, 2018, at 3:19 PM, Richard George via Shop-talk <[email-masked]> wrote:
> 
> Hmmm....  along those lines I suppose you could also just solder an led between the center electrode and the side electrode and hook up a DC power supply - you'd need what, ~50V for a sparkplug with a 5K ohm resistance...  Trouble is I don' t know if the resistor in the sparkplug could dissipate that ~1/2 Watt of power...
> 
> :-P
> 
> Unsubscribe/Manage: http://autox.team.net/mailman/options/shop-talk/[email-masked]
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From: Donald H Locker via Shop-talk <[email-masked]>
Date: Sat, 15 Dec 2018 09:03:06 -0500

1/2W dissipation on a sparking plug should be no problem. Supplying all 
the 1/2W might be a pain, but it could be used to heat the garage. :-) 
Plugs are accustomed to operating quite hot, and (IIRC) 1/2W resistors 
aren't that large. Plugs have _lots_ of surface area for heat 
dissipation - far more than 1/2W resistors.

Enjoy 2019's new project!
Donald.
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