Fuel Injection rebuild - parts finish and plating 1959 900R

[Richard M.]

Re: Fuel Injection rebuild - parts finish and plating 1959 900R

Ian, regarding that nipple, I feel your pain.

This one had a cast iron plug. I tried a impact gun but the square broke off. I ended up drilling out the center with just a thin amount of perimeter left and carefully cut slots in the sides with a hacksaw blade in several places to then tap the segments out with a drift. Then cleaned threads with a NPT Tap. Nerving task.

[Ian G.]

[Richard M.]

Re: Fuel Injection rebuild - parts finish and plating 1959 900R

Ian,

Is that nipple you're trying to remove the stock type? You might want to try a 1/2" drive impact gun first. Abrupt triggering in both directions to try to free it up a bit. Not so much CW though as it's a Pipe Thread and you don't want to go too deep.

I've used my old Craftsman electric 1/2" drive Impact Gun on fittings like that on water pumps etc and have had good luck.

Another possible aid may be a long dosage of CRC Freeze-Off on the nipple close to the manifold. This would shrink the nipple a bit.

If all else fails you may have to cut the nipple flush to the manifold face then segment the pieces horizontally as I did.

Rich

[John D.]

Re: Fuel Injection rebuild - parts finish and plating 1959 900R

Ian, Doesn't take much to pull/destroy the threads on those baseplates/intakes.
Here's how we take them out. Huge old hydraulic press. Two huge pieces of 2x12 or bigger lumber. Sandwich the casting between the wood and then clamp it in the press.
Aero Kroil penetrating oil. Heat it up with the torch. Hit it again with the Aero Kroil. Let it sit for a while. Now everythings we should heat the surrounding aluminum. But we don't do that any more. My helper heates the inside of the fitting big time. Then the fittings typically come out.
Once in awhile nothing works. So then we cut the fitting out.

Poor Rich with the square plug. Wow!!!

[Ian G.]

Re: Fuel Injection rebuild - parts finish and plating 1959 900R

Thanks Richard, as luck would have it , it came right out once I mounted it on the engine temporarily for leverage. ironically, the temp sender that I thought would be easier is proving more difficult. it's completely stripped and cracked, after having at it with a breaker bar and socket. Sucks since I think it was original. I have another though, since I figured a while back it might be destroyed getting it out. I'm going to try a 14" pipe wrench. My compressor is out and needs servicing sadly, and I don't have a big impact drill currently.

Here's a pic of the nipple. Doesn't appear original?

[Richard G.]

Re: Fuel Injection rebuild - parts finish and plating 1959 900R

With a wrench that big (14") you are quickly getting into the amount of torque that will easily pull the threads on the aluminum.
I would consider drilling it out, as far as you can go, without going into the aluminum. This allows the thin wall that is left to collapses and it will usually come out.
I am assuming the sensor shell left in the manifold is brass. You might get lucky on brass but if it was steel I would be drilling it for sure. Often times the issue is not having a large enough drill and drill bit for this job as many home shops only go to 1/2". Beg or borrow or farm out the drilling if you have to. Heating and cooling the fitting several times can also help. If you pull the threads you will be welding and drilling anyway. Slow and easy and not wasting any options before you have to is the trick to successfully pulling these stubborn fittings.
Rick

[Don B.]

[Ian G.]

Re: Fuel Injection rebuild - parts finish and plating 1959 900R

Fred Hudson
405-620-2748
email f.hudson@cox.net

[Don B.]

Re: Fuel Injection rebuild - parts finish and plating 1959 900R

Thanks. Spoke to Fred this morning - very knowledgeable!

[Ian G.]

Re: Fuel Injection rebuild - parts finish and plating 1959 900R

I opted to drill the temp sensor as suggested. I got the insides out. It is 1/2" internal already, so I guess I need a 5/8" bit. Anyone know if the nipple I pictured is original? i think it's a replacement.

[John D.]

Re: Fuel Injection rebuild - parts finish and plating 1959 900R

Ian, Never saw a fitting like yours in an FI baseplate. Never saw it anywhere.
I sent you my catalog. Look at the all the pics of the various fuel injections. On some of them you can see the correct fitting.
NAPA has a really nice fitting. After you see my pics go to your local store. They have two sizes. If you baseplate has the adapter screwed into it then get the applicable one. Nice thing about the NAPA fitting is it has a "restrictor" hole like in the original '63's. John

[Joe R.]

Re: Fuel Injection rebuild - parts finish and plating 1959 900R

John,

Thanks for helping Ian. As you know some inexperienced members will try to show off their quote (workmanship) to obtain work at the expense of trained professionals in this business.
If they want to enter in the business of restoring Corvettes including fuel injection they should spend some bucks advertising in the Driveline and quit using this forum.

Thanks for your expertise,

JR