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James,
the correct way is to pull that new plug (yea, I know, didn't want to hear that) out, and take some steel wool, and clean that lip good, and reseal it (maybe a light coat of silicone tapped in with the plug).
the other option (again involves removal of plug), is to take the new-leaking plug out, and replace with one of the rubber expansion ones, that have a bolt in the center, and allow you to slip it into the hole, and crank 'til the rubber (and inner metal sleeve) has expanded to seal the diameter.
if you don't want to fight another couple hours to remove the plug, a heat resistant, two part epoxy (JB Weld, or equal) mixed, and then smudged all around the plug, (allow it to cure before running engine) may seal the plug, and would still "pop" if freezing conditions forces the plug (or another one) to leave the block.
if you do elect to remove the freeze plug, if you have a dremel, or a 90degree drill, might be easier to make a hole in the center of the plug, and not "bung" up the perimeter of the hole; and if you do have a dremel, would definitely be easier to clean that surface prior to sealing.
if you do remove the plug and re-use it, or get another, if it is in an oddball, hard-to-reach area (they usually all are), find a socket that is the same diameter, or a small block of wood, so when tapping with mallet, or prying/leveraging it into its well, it goes in as straight as possible.
hope this helps,
chris
nrt racing
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