Aurelia engine water tubes

[Florent]

Hello,

I have to remove the remaining parts of the water tubes in the block of my Aurelia 2500 and any advice or experience on the way to remove the bigger cap at the end of the tube would be greatly appreciated.
Is the cap screwed in ? stuck ? press mounted ?
Before I try to push it (risk of breaking block ?), I'd like to have informations from someone who did it.

Many thanks in advance

Best regards

Florent

[Walt Spak]

Florent,

The water tube plugs are pressed into the block and then the block is swedged around the plug. If you try to push or pull the plug out, it will break the alumimnum of the block. I have found that it is best to machine the plugs out. Measure a new plug and machine untill you have an interferance fit with the hole that you are machining. I use a sealant on the plug just for good measure and then swedge the block back around the plug. You need to make a tool for this.

Any other ideas out there?

Walt

[Steve Katzman]

When I have the time I like to machine a seat and thread for a brass plug, DIN 908, on both ends. The plugs
take an allen key. It takes a bit of effort, but makes it easy to get back in if you ever want to (god forbid). You
may may need to chamfer the edge, and yes, use a sealant or copper washer.

I've used a seat and guide machine, but a vertical mill might be more stable. I've thought about attaching a
magnesium sacrificial anode, especially as it's in the coolant flow.

Walt is right about removal, you don't want to chip out the block, or gouge the sealing faces. I've also used a
hand drill to hog out the centerline of the plug, and then a die grinder to CAREFULLY get close to the edge,
and then using a punch to move the plug to the middle.

Good luck,

Steve

[Florent]

Many thanks to Walt and Steve, I will keep your advices in mind and machine the plugs.

Best regards

Florent