I think that it would be possible to temper the washer, clean and re use it.
But getting some larger size washers is a good idea.
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I tapped my sump oversize with an NPT thread then bought a Fumoto drain plug off eBay, this fixes the original problem and saves ever taking the sump plug out again. The original sump plug is recessed so if you go oversize the head if the bolt is tight into the recess and makes tightening up challenging.
Cheers Marty
At the end of the day what is the cost of a replacement engine for the sake of $60.00 [wink11]
No matter what the cost is do it right do it once or you will get hit with a far larger expense than what you are stressing about[thumbsupbig]
Remember your provent bracket [bigwhistle] Do it right the first time[wink11]
Fumoto units are bloody horrible!!!
Too bulky, too heavy, and not protected by a secondary protection of a sealing Cap...
Too many potential points to go badly wrong! Add to that no method of draining any better - it still just pours out...
Look at something like a Stahlbus or similar - theres another thats more compact of you like.. When you want to drain you screw on a hose fitting and the oil cleanly and easily goes directly into the container and nowhere else!
The Stahlbus comes with a 'Race Cap' option which can be secured once attached to prevent coming loose.
Here do you really want this hanging off your sump just waiting for something to hit knock it off on your next off road venture[bighmmm]
Plenty here if it you really want to tempt fate[bighmmm]
Fumoto drain plug | eBay