I'd still try to drill that plug and use a twist out. Have you tried a titanium
drill bit or asked the hardware store guy for a super hard bit. If you can get
the plug out you'll get a lot less metal bits in your gearbox than
drilling/tapping a new plug hole.
If drilling is the only option then you might want to try drilling "around" the
plug to get it out (e.g. drill right next to it with a very small bit until you
can get it and then tapping the hole. You'd have to find a slightly larger plug
but at least you'd only have one hole and at the correct level and location.
I don't know the pitfalls of another hole in the same area. I'd be afraid of
nicking a gear or something in the process, but it might be possible if you have
a good idea of what's on the inside of the gearbox at your new plug location..
Good Luck
Bud
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