1999 V70 Ridiculously Rounded Drain Plug Advice

[regent]

OK,
I have now realised that my only option is to officially withdraw my redneck-tap-a-drain proposal and to admit solemnly that I had never done that sort of fix myself... (Maybe because my mother-in-law never trusted me to work on her car )

And many many thanks to everyone who pointed out the downsides; I believe we are all learning a lot about what not to do and why, and all sorts of thing that they don't teach you in school.
Thanks!

[deepsouth]

Update. It still holds fast. Below is a new picture of the bolt after my numerous assaults, and the tools that I have used thus far, including the Channellock Nutbuster (great tool but no dice). Also in the photo are the three Irwin Bolt Extractors that I've used (notice the decreasing sizes).

My next plan of attack is the drill. I welded an Easy Out to an extension that takes a 3/8 drive. I plan to drill successively larger holes until I win. Sounds simple, eh? At this point I'm embarrassed to report that I've spent almost as much time working on this bolt as I have pulling the entire head. It's become personal.

[Ben850]

I don't see a hacksaw blade in that collection of tools.
My suggestion earlier in this thread has worked for me. If you continue taking material from the perimeter of the bolt head, you will never get a chance to try it.

[timmybdaddyof3]

this sick joke will become when there is nothing left of the head, you pull the pan and find out the previous owner welded it from the inside

[deepsouth]

My suggestion earlier in this thread has worked for me.

The problem is that it's recessed from the top and the cooler (or whatever it is) to the right. There's barely enough room for the Nutbuster, let alone something to put in the bolt and turn sideways. If this was a 1998 or older I'd have plenty of room, but this is very tight.

this sick joke will become when there is nothing left of the head, you pull the pan and find out the previous owner welded it from the inside

That would at least explain it. It doesn't even seem humanly possible to for it to be this stuck.

[cn90]

Take it to local muffler shop and ask them to weld another nut to it (labor is about $10-$20 for welding this simple).
Then undo the bolt.

Make sure you have a new drain plug ready...

[deepsouth]

That's a good plan, but last Wednesday, I pulled the head and it's at the local machine shop getting squared away. It'll be another week before I can put the head back in but I'm not in any hurry. Just always nags at me when I can't fix something.

[cn90]

Sometimes you have to "lose a battle but you win the war".

[dosbricks]

Well, the head is getting progressively smaller, and with it the chances for abscate's 1000 Dong bet on the heat and chisel method grow steadily slimmer.

BTW, when my 366 were up, I put my Dong to good use in Ben Hoa.

[abscate]

Well, the head is getting progressively smaller, and with it the chances for abscate's 1000 Dong bet on the heat and chisel method grow steadily slimmer.

BTW, when my 366 were up, I put my Dong to good use in Ben Hoa.

There are over a million people in Bien Hoa now, btw.

Thank you for your service.