First I would buy a new sump plug to use after you've got the old one out.
Sometimes you can get them out by hammering on a smaller size socket. A bit brutal but it does work!
Otherwise use a stillson. It's the tool that engineers and plumbers use to turn bars and pipes that are completely round. Get one with a long handle so you can get plenty of torque. Just don't do the new sump plug up with it.
Use a torque wrench to do up your new sump plug, at the correct torque setting, and use a new washer!
I had an identical problem. The way that I finally removed it was to use a small hacksaw and very carefully cut two flats opposite and parallel to each other on the head of the plug. Be careful to cut down only as far as the copper sealing washer and do not cut beyond the diameter of the threaded section of the plug. Then with a pair of good large molegrips, clamp across the new set of flats and you should be able to loosen.
get your local welder/garage to weld a decent sized nut to the bung then problem solved.... i've had to do this a few times on fords with ally sumps where someones over tightened the sump plug. shaun
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