Screw in freeze out plug removal

[fekbmax]

Ok guys, any tips, tricks, curse words, that I can use to get these steel plugs out of this pond aluminum block . ? Heat got two out but 4 don't want to budge. I'm about ready to just drill and cut them out since I'll be replacing them anyway. The block needs a good bit of welding and repairs so I need to have it completely stripped down. Already got the sleeve's out.

[jayb]

The only way I've seen it done is with heat and a big impact wrench.

[blykins]

Steel plugs in an aluminum block?  All of my Pond blocks have had aluminum plugs with o-rings.  I have a piece of hex bar that fits the plug and I use a wrench/socket on it to remove the plugs.

[jayb]

That's interesting, my Pond block has steel plugs.  Maybe a running production change?

[blykins]

I have never seen an aluminum or cast iron Pond block with steel plugs, but the first one I touched was in 2010-2011.  Must have been a design change.

What's Jason's block have?

[fekbmax]

The two that I was able to get out are the thick steel plugs like Dennis (DSC motorsports) has and not the thin steel plugs such as Barrie normally has. It was a used block for m so idk if they had been changed or not. I'll run it by a friend's truck shop this weekend and see if some heat and one of there stout impacts can jar them out.. My little home shop stuff just ain't gettin it..
Thanks guys..

[Phil Brown]

I would heat the area around the plug (not the plug) first ,might take a fair amount of heat to get it to let go. But watch the threads,don't take them out with the plug
If there that stuck do they really have to come out ?
                                                                                       Phil

[fekbmax]

I have gotten two out and applied so much heat to the rest that I would be afrade they would now leak if I left them in. My welder really wants them out so he has max accessibility to weld the patch pannles in I have made. I want to give him what he wants because he is an amazing welder (NASA) and a great friend. He loves a challenge and I'm all about saving a pot full of cash n repairs.

[TJ]

Had to remove a screw in freeze plug that had been in a diesel tractor for 50 years.  Broke a craftsman four inch long 1/2in drive extension using four foot pipe on my socket wrench trying to turn it out.  Was afraid to damage the block with an impact wrench.  Drilled three holes in a triangular pattern and then sliced the plug with a hacksaw almost to the threads.  Tapped the slices of plug out with a chisel.  Took forever but at least I didn't damage the block or threads and was able to install a screw in block heater.

[KMcCullah]

Hey Keith- Have you tried the birthday candle trick yet? Warm the aluminum around the plug and melt a few candles around the threads. It's like sweating copper except your using a candle instead of solder. It might take a few tries. Good luck.

[Heo]

This is the way i do it. I bore out the center of the coreplug.
 Then i make a Plug thats smaller than the hole by about 1/2 inch.
And so much longer than the coreplug so you can mill two sides flat
for a wrench or weld a lever to it.
 Put the plug in the hole in the coreplug weld i to the coreplug.
 A good massiv weld and let it cool for a while.
 The cooling weld shrinks the coreplug.
Now you can take a wrench to the flat spots you milled or
weld a lever to the plug and losen it with ease.
I use the same metod when i change valve seats in heads
without the wrench  though. the often fall out by themselfs
or a light tapping with a punsch through the valve guide

[Qikbbstang]

If your going the screw around with cutting into the plugs (hacksaw?)  to relieve pressure/get at threads with penetrating oil use a die-grinder and a carbide burr