OK, I sawed two slots and used an awl to pry out the pieces. Worked
like a charm. I could not get it to break loose with the easeout,
probably due to lack of strength or leverage.
Thanks everyone for your help.
Libby

sdlomi2 wrote:
> > wrote in message
> oups.com...
> > 96 Chev Truck 4.2 V6 - 160,000 miles. It was seeping water out of the
> > bottom of the aluminium nipple thing that has a quick disconnect
> > attached to it. When I touched it, the nipple snapped off flush with
> > the manifold. My question is, what is the best way to get the rest of
> > the nipple out of there? Looks like an Ease-out might do it but I
> > thought there may be some other techniques. The remnants are highly
> > corroded and soft. Also, if little bits of aluminium fall down into the
> > hole, will this damage the motor in any way? I thought about heating it
> > with a torch to see if the aluminium would melt out of the threads
> > or maybe threading a steel nipple in there to push the rest of the
> > nipple down into the manifold?
> >
> > Thanks,
> > Libby
> >
> As other posters have suggested, sawing into the remaining nipple, try
> just ONE slot for starters. And use only pulling strokes with the hacksaw
> blade so as to minimize filings going into the manifold. Once this slot is
> cut, use of a punch or awl to peel the remainder out. Often just one slot
> is sufficient and one scored slot partially thru the manifold threads can
> easily make a fluid-tight connection, using proper dope when assembling.
> If the filings-into-manifold concern you so much, you could insert a
> small rag(or piece of one), with a strong cord attached around a corner for
> later removal. Holding it firmly against the bottom of the hole, you can
> carefully remove it, along with many of the filings, when the sawing is
> completed.
> Other tips often helpful: grind a single, fine-thread blade, so as to
> make it narrow enough to allow cutting strokes inside that hole. For a
> handle, wrap a shop rag around the upper end to make a comfortable, safe
> handle.
> HTH & good luck, s