Coleman Drain Plug Replacement

Complete drain plug assembly for a Coleman Xtreme cooler.  The original Coleman design is just a push fit plug but the drain body exposes a bit of thread which could support a threaded plug.  This is what I decided to make.

This particular design is for a 1.5" drain.  If you need the 1" version I could add it, but I would need a couple dimensions of that part.

The thread pitch is a custom metric thread with 2mm pitch on 19mm outside diameter.  This is very close to the Coleman original threads which are also 2mm pitch but have a strange cross section.  You can just print the plug alone if you want.  It will thread onto an original drain body quite nicely.

Print in PETG.  Lightly sand the inner bore of the drain so that the plug fits in snug.  It will likely come off the 3d printer a bit too snug without a light sanding.

You will have to work the threads back and forth a number of times to loosen them up a bit.  This was intentional as I don't want it coming loose.

Print with supports on the plug to keep the groove dimensions accurate and supports on the top row of threads on the nut/lanyard piece.  Remove the supports on the cap and lightly sand the groove.  Stretch the nut lanyard ring around the plug.  Work it in a bit and it will spin freely.  I have also added a cap which has a much larger gripping surface if you prefer.

The hex notches in the body are for a 12mm hex which aids installation greatly.