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OK, here is the full progression...I started with a 5/16 Allen wrench that has a 3/8" input, driven by the 1/2" impact wrench with a 1/2" to 3/8" adapter, and there was no movement. In the past, I had a similar situation on a tire 7/8" nut that didn't come out with the impact wrench, but it did...

Yes, I think heat is the key, I did try the vice-grips (larger ones to get more torque) and it took off pieces of the plug head without any plug movement. If the plug Allen head wouldn't have stripped first, then the 5/16" key would have broken, it was already twisted half way. I will give the...

You are exactly right, I love metal and have many other tools, the welder seems like a missing piece. If I go the welding route, I would still get someone with experience to do this job while I get up to speed practicing.

I would definitely pay someone to do the welding.

I didn't think it will be this stuck as I had other stubborn ones, but which eventually gave in, but this one...gave nothing. I did think about the heating (I have a propane torch) but AFTER the fact lol...of course...I can still do a few last resort heating/ cooling cycles to see if I could get...

Yes, it makes total sense and I have new drain plugs, just never welded before. The closest similar experience I have is soldering from millimeter electronic parts to water copper pipes. I could get a welder and give it a shot, it seems like a pretty low risk job?

As I posted in another thread, one of the geared hubs drain plugs was stuck, the Allen key bent so much, I thought it will snap (it felt like 100 ft lb or even more). And with each pull, the drain plug head had more play...not good. I put some penetrating oil, but the whole thing is upside...