Re-use head gasket?

RTV cures when exposed to air. You have to let it setup a little bit before you close it off or else it will stay wet. General rule is to let it set for 10-20 minutes until it forms a visible skin, then install the part and let it set for another 10 minutes before driving it in.
 
I am using a 33mm impact socket (bought it for pitman arm nut), which fits almost perfectly inside the lip. I have one socket that fits even better, but it actually gets stuck once the plug is driven in.

I will see if I can scrounge some more plugs around town today, then try it again letting the permatex set up longer before driving them in.
 
I'd put them in slightly recessed. Didn't see, what are you using to push them in? Not something that fits the OD, right? You should be using a socket or something that drops down in the middle, probably 3/4 of the X OD.

X2. Do not forget to recess them in just a hair. I forgot that one time and all looked ok till it got hot and I lost one going down the road. So I had to redo that one and I just tapped the others back into the block a bit more for good measure.

I just used some black rtv on mine when I installed them and let them set while I finished putting the head on. I have not had an issue yet and it's been over a year.
 
So I thought I would post an update.

I finally got it all back together last weekend. I had the freeze plugs installed leak-free a week before that, but when I reinstalled the head the tail of a zip-tie managed to get stuck between the head and the gasket, towards the back of the engine where it is difficult to see. Didn't notice it until I was trying to put the rearmost pushrod in, and something was blocking it. Removed the head and luckily nothing was damaged or cracked. So I had to wait for new headbolts and gasket to arrive. (tally for the entire operation: 3 head gaskets and two new sets of bolts).

Anyways, the sealant I used for the succesful plugs was Indian Head Gasket Shellac. I put a good smear of it around the bore and around the plug lip, and let it set up for about 20 minutes, until it is semi-hard. After driving it in as carefully and as straight as possible till it was just inside the edge of the bore (less than 1/16" usually), I let it sit for 24 hours before I filled it with coolant.

Besides the gasket shellac and letting it set up, the other important thing was driving them in straight and true. This is obvious, but with the engine in the car it is much easier said than done. There is not much room to swing a hammer, and the angles are awkward. I could not usually get enough oomph with my little plastic dead blow hammer, which I would rather have used. Instead I had to use a 2 lb sledge.

The key is to tap as gently as you can, and constantly observe if it's going in straight, and do correcting taps as soon as you see it off kilter. Usually it would start getting off slightly when I started it in, and then I had to use correcting taps the rest of the way. But if it get's too far off you really need to pull the plug out and trash it, since it will get deformed and will not seat as well, even if you can knock it back straight. If I had access to a hoist I would say that it's worth it to pull the motor to do this right.

Over the course of this I used several different manufacturer's plugs, including Dorman, Sealed Power, and Clevite (found the dorman at O'reillys, the others at NAPA). There were slight differences in cup depth, and even in diameter: the brass clevite plugs were a hair wider than the others, and you couldn't even start them into the bore without a hard whack, which usually got them in crooked. I had to throw all but one of those away. Most of what is in there now are Dormans, marked "2005" (there are other Dorman plugs that are labeled "CHINA", these have a shallower cup). But I had leaks with all types of plugs, so it's probably not an issue with a certain manufacturer.

I'm still not completely sure why so many leaked. It had to be some combination of wrong sealant, not letting the sealant set-up before driving them in, and not driving them in straight and to the proper depth.

Anyways, hopefully this can help someone in the future.

Now that I've written all this, one of the plugs will probably blow out on the freeway.
 
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