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.
69 Camaro Z/28 RS, original Azure Turquoise, M21 & 3.73 12-bolt posi. NOM 406ci, AFR 210 heads, Straub hyd. roller cam & Dynatech 1-3/4" > 1-7/8" headers, QuickFuel 750 Annular. Photos at:
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