How To Remove A Welch Plug

Removing and installing the Welch plug for the Walbro WG carburetor was updated November 7, 2019These notes are for Walbro. Others are similar. Only in rare cases will you have to unplug the Welch Read: how to unplug the Welch There are two ways to remove the Welch plug One way is to use the Walbro 500-16 tool. However, the tool is expensive ($33 and up) and requires skill to not damage the Welch plug and the small segments below it. If you have this tool, hold the punch at a shallow angle to the Welch plug and push it through with a hammer. Of course, if you don’t do it correctly, you’ve damaged the carburetor. Universal kits for removing Welch plugs in various carburetor build-ups are available, but they are also expensive ($70-$150) and contain more tools than are needed to service the Walbro carburetor. The figure below (by Walbro) shows the exact angle.The second (and much easier and better) way to remove the Welch plug uses the following tools:

A drill press (best) or a drill chuck (take out one of your electric drills) Note: If you have special skills with a hand drill, you can use it. You must stop as soon as the bit goes through the Welch plug.
3mm (1/8″) or 2.75mm (7/64″) drill bit. Size is not important.

If you remove the chuck from the power drill, note that the center screw that holds the chuck from loosening has a reverse thread. To install the plug you will need this tool:

punch, rod or bolt slightly smaller than the diameter of the Welch . plug

Remove the plug

Secure the carburetor in a cover, if possible, use (2) pieces of wood to protect the sides of the carburetor throat. Holes are best made with a precision drill or by hand, slowly and carefully. Apply steady pressure until the bit begins to penetrate the plug. At this point, pull upwards just enough to keep it from reaching the bottom of the well. It is relatively easy to cut through aluminum with a bit of sharp steel by hand. The tools used below are specially made to remove Welch plugs, but chucks and bitches work the same way. Thankfully, if the hole is centered on the plug and goes all the way to the bottom, none of the inactive progression holes can be damaged.Once you’ve made the hole, push the pushpin or the other end of the freshly drilled bit into the hole and move the awl to the side. The plug will come out right away.After unplugging, clean the hole thoroughly with compressed air. The best way to do this is to use a compressed air tool with a very narrow tube or a can of compressed air used to clean computer keyboards. Place the tube in a corner of the well with no holes, gently press down on the tube and let air in. The air will flow over the surface of the main hole (but not directly down the small holes) and it will remove aluminum flakes from the hole drilled in the plug. Also blows air through the main nozzle to supply both the nozzle in the carburetor throat but also the idling circuit. This part of the circuit that does not work may have debris from drilling holes in the Welch plug.Read more: how to do elbow planting Then clean the carburetor with compressed air and carburetor cleaner. Examine the carburetor carefully with a magnifying glass. You must make sure it is completely clean and free of any debris. Small holes in no-load circuits can be visually inspected with a bright light to ensure they are clear. When done, continue with the steps below.

Plug in settings

Use an awl or bolt to place the Welch plug. If you use bolts, make sure the end is flat. When using any tool, be careful not to come into contact with the soft rim of the hole. Precisely center the hole, rod or bolt on the top of the plug and tap gently with a small hammer to smooth the convex surface of the plug. This seals the plug. The plug must be flat or it may interfere with the operation of the diaphragm to be metered. If the plug leaks, the mixed needle that does not work will not work properly.Welch plug is finished. When the convex side is flattened, the plug expands and seals the well mouth.Reassemble the carburetor, adjust and check. Read more: How to clean a well-fitting hat

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