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What do I do now? Just take the whole engine cover off?

I was using the opposite end of the original spark plug tool - always worked before!

Does anyone have a spare cap to sell?

Been there, done that.
Use water pump pliers (multigrips) and/or hammer+chisel to get it off, get a new one and a suitable Allen key.
I re-purposed my chewed up one as a slide hammer attachment to help remove the clutch cover.

Jordan

Hi Jim, I'm pretty sure I've a spare ( non Esso or Agip marked) plug you can have.
Only trouble is its in Brisbane.
If you want it I can mail it but it may take a while to get to you.
Graeme

Hi Graeme,

Thank you for the generous offer. I bought what I am sure is a repro off of eBay about an hour ago.


Still struggling to get the old plug out though. I grabbed it pretty well with vice grips but I couldn't get it to budge.


Is this the dissimilar metal thing going on?


Should the threads on these be treated with anti-seize?

Should be ok with brass and alloy,
Try warming the case to expand it a little, then a sharp hit on your vice grips with a rubber or plastic hammer.

Hi Jim
You could try jamming a tight fitting chisel in the hex & then turning the chisel with a shifter. Or maybe a tight fitting flat blade (or even a hex if it's not to mutilated) & an impact driver. Heat will help a bit so maybe best with the engine hot, although brass is not that dissimilar to the alloy over a small temperature range. Failing that you could get someone to tig braze a hex into the plug & then use that to undo it. A more drastic DIY solution is to remove the cover by gently tapping it with a soft mallet & drill & tap the plug something like M8 or 5/16" (drill the plug from the outside to avoid to much swarf getting in the bearing . Then screw an M8 (or whatever size you use) bolt in the bearing side with a spacer on it to bring the bolt head proud of the bearing. Then just tighten the bolt & the plug will come undone. Afterwards clean everything thoroughly to ensure there is no swarf in the bearing or casing.

Good luck Nigel

Thanks guys.

Unfortunately it's a job for next weekend at the soonest now...

I will report back when I have it out.