Removing plug from 163...

[WILMASBOYL78]

Need some advice on removing the plug from a 163 aluminum intake. This is the plug next to the thermostat housing, driver's side. Would like to install temp sending unit in this spot...have tried some penetrating solvent and lots of muscle..but it won't budge. Any thoughts...

wilma

[CamarosRus]

KROIL !!!!!!!

http://www.kanolabs.com/

Honest enough to admit I Cracked a 163 trying all the tricks to remove misc plugs.
Candlewax
Drilling increased sized holes through center

[Mr. Duece]

Tom, what usually works for me is: drill a perfectly centered hole as large as you can before hitting the threads. Do this gradually to be safe. Then take either a hacksaw blade if it will fit or a Dremel type cutter to thin out the remainder of one side. Collapse it toward the center with a punch or a chisel. Pick out the remains. I've done this dozens of times with great success. Hope it works for you. Don

[P.J.]

Try using a small torch heating only the steel plug then use a snap on adapter for the removal of the GM plug on a johnson bar. Failing that and sometimes you can get it out
without ripping the threads right out of the intake.Then if it still does not come out get the plug drilled.
Drilling the plug out with the right diameter drill for a pipe thread. Yo must first centre drill the plug with a centre drill, then step drill with the proper dia of the
size needed to tap the pipe tread. It would be advisable
not to drill the plug by hand as that creates a larger hole
than necessary.See if you can get a machine shop to do it for you at a reasonable price.They can also use a plunging endmill on a Milling machine. Sometines its cheaper than buying a new intake or have the intake welded and then
reworked.
PJ