Iron pipe plug frozen in Aluminum intake - Team Camaro Tech
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post #1 of 33 (permalink) Old Jul 2nd, 15, 05:56 PM Thread Starter
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Iron pipe plug frozen in Aluminum intake

I've tried penetrating oil, brute force, etc....

Not budging a single bit

Thoughts?

I am hesitant to put heat on the aluminum intake (even thought it is off the car)...

Keith
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post #2 of 33 (permalink) Old Jul 2nd, 15, 06:24 PM
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Re: Iron pipe plug frozen in Aluminum intake

Good luck bro. Just had the same problem trying to get a stainless steel ball out of an aluminum drop hitch for my jeep. Tried everything and when all else failed, had that damned thing cherry red from torching it - was not letting it beat me even if I had to throw it away from heat damage........Pfft. It won! Iron might be different and you might get luckier than me.
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post #3 of 33 (permalink) Old Jul 2nd, 15, 06:28 PM
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Re: Iron pipe plug frozen in Aluminum intake

Are you wanting to use that threaded hole for something else? Any reason you can't just leave it in there?

Heating it cherry red really isn't a good option in this case.

Assuming it is a factory plug with the 3/8 square drive. Correct?

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post #4 of 33 (permalink) Old Jul 2nd, 15, 07:04 PM Thread Starter
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Re: Iron pipe plug frozen in Aluminum intake

It is a 1/2" square plug--the square part is not recessed (it sticks up)....No reason I cannot leave it, but want the option to use that location for a temp sender maybe.

Keith
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post #5 of 33 (permalink) Old Jul 2nd, 15, 07:26 PM
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Re: Iron pipe plug frozen in Aluminum intake

Propane torch and penetrant. Heat/cool a few times then heat and try to remove it. Don't be afraid to let it sit for a few days.
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post #6 of 33 (permalink) Old Jul 2nd, 15, 07:40 PM
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Re: Iron pipe plug frozen in Aluminum intake

I was also going to say PB Blaster bath for a few days then heat and cold from a cold source such as a dust off can on the plug area.


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post #7 of 33 (permalink) Old Jul 2nd, 15, 07:50 PM
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Re: Iron pipe plug frozen in Aluminum intake

Get the plug hot with a propane or acetylene torch and then press a candle at the base of the plug and aluminum manifold. The wax will seep into the threads and it should come out.

Good Luck
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post #8 of 33 (permalink) Old Jul 2nd, 15, 08:51 PM
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Re: Iron pipe plug frozen in Aluminum intake

I would try Kroil penetrating oil....that stuff is the best. I can't tell you how many times this stuff got me out of a jam. much better that PB blaster, Liquid wrench, wd40.

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post #9 of 33 (permalink) Old Jul 3rd, 15, 12:09 AM
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Re: Iron pipe plug frozen in Aluminum intake

AERO KROIL is probably the best penetrant but that wont work either .
The only way to get hat out without wrecking anything is you have to shell it out. If it is accessible drill a 3/8ths hole right through the center of it . Then with a tree shaped carbide burr mounted in an air driven rotary grinder go back and forth from side to side up and down the whole length of the plug . Keep removing stock when its thin enough you can collapse it with a small cape chisel or a quarter inch pin punch ground at the bottom diagonal like this / more at a 45*degrees. Use the sharp side to collapse it . Works every time. then run an appropriate size pipe plug through to clean the threads and your all set . I have done this hundreds of times in 45 years works on cars trucks plumbing house boilers industrial boilers etc etc anything with pipe threads . Alex
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post #10 of 33 (permalink) Old Jul 3rd, 15, 03:34 AM
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Re: Iron pipe plug frozen in Aluminum intake

I agree, heat it up, spray some PB or Kroil on it, and let it cool. May have to repeat a few times....and if all else fails, drill and re-tap.

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post #11 of 33 (permalink) Old Jul 3rd, 15, 04:52 AM
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Re: Iron pipe plug frozen in Aluminum intake

I believe metal expands when heated. that being said I have always heated the metal surrounding the part I want to remove
this is just my experience. yours may vary
Example - Expansion of an Aluminum beam

An aluminum construction is designed for temperatures ranging -30oC to 50oC. If a beam's length is 6 m when assembled at 20oC - the shortest length of the beam at minimum temperature -30oC can be calculated as

dl = (6 m) + (6 m) (0.000023 m/moC) ((-30 oC) - (20 oC))

= 5.993 (m)

The longest length of the beam at maximum temperature 50oC can be calculated as

dl = (6 m) + (6 m) (0.000023 m/moC) ((50 oC) - (20 oC))

= 6.004 (m)
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post #12 of 33 (permalink) Old Jul 3rd, 15, 06:25 AM
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Re: Iron pipe plug frozen in Aluminum intake

If it off the car how are you holding it down to be able to get leverage when trying to remove the plug?

Have you tried an impact wrench?

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post #13 of 33 (permalink) Old Jul 3rd, 15, 06:34 AM
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Re: Iron pipe plug frozen in Aluminum intake

Quote:
Originally Posted by Vega$69 View Post
If it off the car how are you holding it down to be able to get leverage when trying to remove the plug?

Have you tried an impact wrench?
X2, that was my thought as well, use an impact and some penatrating oil.
You would be surprised how many lil whacks from an impact will overcome you trying to use brute force.

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post #14 of 33 (permalink) Old Jul 3rd, 15, 07:15 AM
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Re: Iron pipe plug frozen in Aluminum intake

Quote:
Originally Posted by reelknots View Post
I would try Kroil penetrating oil....that stuff is the best. I can't tell you how many times this stuff got me out of a jam. much better that PB blaster, Liquid wrench, wd40.
X 100

Give it a shot of Kroil every day for a week...Kroil penetrates gaps down to 2 microns.

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post #15 of 33 (permalink) Old Jul 3rd, 15, 07:48 AM
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Re: Iron pipe plug frozen in Aluminum intake

I'd come up with a socket that will work on the square male fitting that interfaces with a 1/2" impact gun. Then I would carefully heat the intake manifold around the plug to expand it and hit it with Aerokroil penetrating fluid or a transmission fluid and acetone or diesel fuel 50/50 mix to aid in the penetrating fluid getting in between the threads. I'd repeat this a few times initially and then after a few treatments and following the most recent treatment while still hot and lubricated try backing it out with the impact gun and socket. If it doesn't start to turn, give it a few more treatments and try again. Once it does start to turn, don't try to turn it out all at the same time. Re-lubricate it and turn it in a bit, then back out a bit more and so on while keeping it well lubricated. With patience and care there is a good chance you can successfully remove it.

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