any suggestion on how to get the 6mm plug out for lube change now that the 6mm hex key rouned out the inside of the plug. A whole new stator? is not in my budget.
thanks

after looking at parts list, i see the plug is actually 1/4 hex. the 6mm was really close, and so far I am to scared to pull hard on 1/4 hex wrench since I have stripped away some metal, maybe I will get a 1/4 hex socket drive so I can hammer it in before turning with breaker bar. maybe with a socket drive I could get it mated to hand impact driver.

The good news is those plugs are brass (soft), so they'll give before you damage the stator housing.

No matter what you do, take the stator off the jetdrive so you can set the stator impeller-shaft-side down. This will put the brass plugs "up", easier to work on and better to control any chemicals you might use. Speaking of that, I would use some penetrating oil or similar product to loosen things up a bit regardless of how you plan to remove the plug.

It sounds like you used a slightly too small hex wrench. If the 1/4 inch (proper) size will still fit, but you're worried about stripping out the plug, one approach would be to get a sacrificial 1/4 hex wrench and epoxy it into the plug. All you're trying to do is prevent it from turning relative to the plug; there may be enough metal to prevent that with the proper sized wrench anyway, but JBWeld will almost guarantee it. Obviously be careful not to let any epoxy near the plug's threads. The plug is already a loss, and a sacrificial hex wrench should be cheap.

The other option is to go to a machinist's supply house (look them up in the Yellow Pages) and buy the appropriate size of reverse thread (aka "left hand") drill bit. This is like an EZ-Out but works better. You want it just smaller than the female (stator) threads so it doesn't damage the stator. Use a LOT of pressure and drill VERY VERY slowly in reverse. The idea is to have the drill bit engage the plug, not drill it out; going slowly encourages engagement, while going fast encourages cutting. Once the reverse thread drill bit engages the plug it will likely just unscrew the plug like normal.

If you find that the drill bit insists on cutting rather than engaging, try countersinking with a smaller drill bit first. That will present edges to the tip of the reverse drill bit. This shouldn't be necessary with a hex-head plug, though, since it already has a hole in its top.

Again, press HARD on the drill motor. You do not want the bit to slip against the plug. You want it to bite in.

This problem is easy compared to the one I had: I stripped out the head of one of the Torx-head screws that hold the stator to the ride plate. That one was a nightmare. Nothing worked, and I ended up having to drill off the head, remove the plate, and then back out the shaft with vise-grips. All better now, though.

Good luck and report back!

Thats what I would first (manual hammer driver with the tightest fitting hex key i could tap in snug)but I would spray some blaster on the threads and let it sit for a day first. Maybe it will eat some of the corossion off? If that doesent work then you will have to drill it out. Its really not that big of a project, let me know if you need help with the process.