people who say its not the tool its how you use it are wrong,
you need a really long tool

my sump plugs always seem to be rounded off, its a real pain because there is so little 'head' to grab onto.

Anyway as others have suggested, i just use a punch and tap tap tap it with a hammer, comes loose and the nut is still fine (apart from a slight dent)

nobody is going to believe this, or you're all just going to think i'm an idiot, and you might be right. but I still can't get this sump plug off, and by still i mean after going at it with a cold chisel and a hammer! All I ended up achieving was taking off even more of the bolt, I've taken off so much of it now I can see the copper washer quite clearly and have cut through it too, I've been very careful not to etch into the sump cover itself though.

Tap wrench time I suppose, IF I can get a drill in there.

DO NOT DO IT!!!

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1967 Mini Deluxe 1275 heaps of modifications
1969 Mini Matic 1100

ok? -- what then? i'm stumped! still!

Remember:

Lefty loosy,
Righty tighty.

If it's that tight what you call a `tap wrench' which is really an Ezy-out, will just break off- unless you use a huge sized one.
You will then have a hardened tool stuck in the soft steel plug = An even bigger problem.

My solution?
Find an old socket, drive to a muffler shop, ask em to put on hoist, and MIG weld it onto the plug.
The sump plug will still be useable, but I'd then fit a new one.

BTW the proper size socket or spanner is 15/16".

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DrMini- 1970 wasaMatic 1360, Mk1S crank, 86.6HP (ATW) =~125 @ crank, 45 Dellorto (38 chokes), RE282 sprint cam, 1.5 rockers, 11.0:1 C/R.

lol i've been saying that to myself all day wondering if i'm insane and just not turning it the right way, so i even tried turning it to the right just to rule out me being a complete tool but no, no better.

Only problem is, the car isn't drivable, it's not roadworthy and has no registration. I bought the car about mid way through last year and havn't really done anything to it until now because of time restraints, anyway things aren't off to a great start

As always Dr Mini has a solution.

Drilling /easy outs (NOT) are all going to lead you into a world of pain.

You could also try welding a nut onto the sump plug, and then use the right size socket or ring spanner.
The heat from the welding will also help to loose the plug.

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1967 Mini Deluxe 1275 heaps of modifications
1969 Mini Matic 1100

That sump plug once removed would certainly deserve a picture taken. And then a burial at sea, or off a cliff.

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SooperDooperMiniCooperExpertEngineering

All garage work involves equal measures of enthusiasm, ingenuity and a fair degree of irresponsibility.

I would at Least buy a New Plug

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Stop Licking the Dog...I Don't Care Who Started It

I'm going to figure out away to blow the <MOD EDIT> Offensive language will not be tollerated here , future post's with offensive language will be deleted outright . thing up.

Not sure how much of the plug is left by now but if there is much go down to your local tool shop and buy an impact socket, with only 6 sides they are next to impossible to round a nut off. Someone suggested it already but I didn't read if you had tried it. Also I know you have hit it on an angle with the cold chisel but give it a few firm hits square on, you can also buy a bar that allows you to have a sochet on it and there is a face to give it a hit while you have some weight on the bar, though these put most of the load onto the housing and not the plug.

I have the same issue and will be trying welding an old socket on tomorrow. After evaluating all the options, including Eazi-outs, the only one I can see that will work is the Docs suggestion.