The Ford Barn

tbones · 11-10-2013, 01:07 PM

Please help -i finally got a good pair of original 33 aluminum heads. Problem is -How do i get out two old rusted spark plugs? Not enough left to get a wrench on. All ideas or help greatly appreciated. Regards T Bones

ford3 · 11-10-2013, 01:27 PM

if you can not get a spark plug socket on the plug break out the porciln part of the plug use a sharp punch to break out the insulator it will come out just leaving the spark plug shell, now you can put heat on the inside of the spark plug shell and not hurt the head, the shell needs to be very hot, so be careful, after the shell cools use a penetrating oil and an easy out, use the square easy outs, they dont expand the part like the round twist in ones, this is just one way to do the job, others will come on with other ways to remove the plug

Andy · 11-10-2013, 01:29 PM

I think you will end up drilling them out. I have had zero luck removing rusted stuff from aluminum. Get the porcelen? out and drill the steel as big as possible. You will end up picking the rest out.

David J · 11-10-2013, 01:49 PM

Something that worked for me is as follows . Knocked the porcelain out and drilled small pilot holes into the threaded part of the plug from the chamber side . Slightly favored the inside and went up carefully in drill size until the holes were just touching the tips of the threads in the head . If you chose the spot right you will have severed the inner wall barely and now you can put a vice grip or whatever on the plug and it should back right out as you have relieved all the pressure . I didn't even need to tap on the halves [ plug is pretty much in 2 pieces now ] to get them loose . Be careful and it should be easy .

Brian · 11-10-2013, 05:45 PM

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Knock out the insulator etc. Weld [preferably with TIG] a suitable sized allen wrench into the remainder of the plug. Immediately after welding, [whilst still hot] apply a candle to the sparkplug threads, the wax will melt and 'creep' down the threads. When cooled, simply unscrew. Works good!

11-10-2013, 01:07 PM	#1
tbones Junior Member Join Date: Jan 2012 Posts: 23	Removing old spark plugs from Alum heads Please help -i finally got a good pair of original 33 aluminum heads. Problem is -How do i get out two old rusted spark plugs? Not enough left to get a wrench on. All ideas or help greatly appreciated. Regards T Bones

11-10-2013, 01:27 PM	#2
ford3 Senior Member Join Date: Oct 2012 Location: oroville calif. Posts: 1,453	Re: Removing old spark plugs from Alum heads if you can not get a spark plug socket on the plug break out the porciln part of the plug use a sharp punch to break out the insulator it will come out just leaving the spark plug shell, now you can put heat on the inside of the spark plug shell and not hurt the head, the shell needs to be very hot, so be careful, after the shell cools use a penetrating oil and an easy out, use the square easy outs, they dont expand the part like the round twist in ones, this is just one way to do the job, others will come on with other ways to remove the plug

11-10-2013, 01:29 PM	#3
Andy Senior Member Join Date: May 2010 Location: Kerrville, Tx Posts: 2,770	Re: Removing old spark plugs from Alum heads I think you will end up drilling them out. I have had zero luck removing rusted stuff from aluminum. Get the porcelen? out and drill the steel as big as possible. You will end up picking the rest out.

11-10-2013, 01:49 PM	#4
David J Senior Member Join Date: Jun 2010 Location: St Croix Falls WI Posts: 2,080	Re: Removing old spark plugs from Alum heads Something that worked for me is as follows . Knocked the porcelain out and drilled small pilot holes into the threaded part of the plug from the chamber side . Slightly favored the inside and went up carefully in drill size until the holes were just touching the tips of the threads in the head . If you chose the spot right you will have severed the inner wall barely and now you can put a vice grip or whatever on the plug and it should back right out as you have relieved all the pressure . I didn't even need to tap on the halves [ plug is pretty much in 2 pieces now ] to get them loose . Be careful and it should be easy .

11-10-2013, 05:45 PM	#5
Brian Senior Member Join Date: May 2010 Location: Masterton, New Zealand Posts: 3,834	Re: Removing old spark plugs from Alum heads Sponsored Links (Register now to hide all advertisements) Knock out the insulator etc. Weld [preferably with TIG] a suitable sized allen wrench into the remainder of the plug. Immediately after welding, [whilst still hot] apply a candle to the sparkplug threads, the wax will melt and 'creep' down the threads. When cooled, simply unscrew. Works good!