Removing a rusted boiler plug

Removing a rusted boiler plug

PostBy: stoker-man On: Tue Sep 08, 2009 8:12 pm

Most homeowners never have to do this, but on this forum there are many DIY, so I'll pass this on. The plug in the picture is one inch. The tools I used were a cut-off wheel, a drill, and a reciprocating saw.

aaextra 043.jpg
(130.02 KiB) Viewed 34 times
View: New PagePopup • Select:BBCode
[nepathumb]13869[/nepathumb]

Cut or grind the square casting off the plug leaving some thread exposed beyond the face of the boiler fitting. Drill 4 small pilot holes.

aaextra 054.jpg
(147.54 KiB) Viewed 28 times
View: New PagePopup • Select:BBCode
[nepathumb]13870[/nepathumb]

Enlarge the holes a little at a time in a sequence. Drill all the way through and hopefully you'll have an opening large enough for a saw blade to go through.

aaextra 052.jpg
(156.44 KiB) Viewed 32 times
View: New PagePopup • Select:BBCode
[nepathumb]13871[/nepathumb]

Cut towards the edge but not into the steel threads. The hole is tapered. When you make contact with the steel, the screeching will warn you. It is only necessary to get within a 1/16" of the steel. Cut into quarters and then make an eighth cut to make it easier to punch that piece out. The rest of the pieces will then fall out.

aaextra 050.jpg
(149.81 KiB) Viewed 22 times
View: New PagePopup • Select:BBCode
[nepathumb]13872[/nepathumb]

Punch the pieces out. Retrieve the pieces with a thin pencil magnet. It should take less than 10 minutes for each plug.
stoker-man
 
Hand Fed Coal Boiler: 1981 efm wcb-24 in use 365 days a year
Coal Size/Type: Anthracite/Chestnut
Other Heating: Hearthstone wood stove

Re: Removing a rusted boiler plug

PostBy: 009to090 On: Tue Sep 08, 2009 8:38 pm

Good tip, But should I use this procedure AFTER I twisted off the square end of the plug? Or BEFORE the frozen plug gets messed up by trying to remove it?
009to090
 
Stoker Coal Boiler: EFM 520 HighBoy
Hot Air Coal Stoker Stove: DVC-500 x 2
Coal Size/Type: Anthracite Rice

Re: Removing a rusted boiler plug

PostBy: coal berner On: Tue Sep 08, 2009 9:07 pm

stoker-man wrote:Most homeowners never have to do this, but on this forum there are many DIY, so I'll pass this on. The plug in the picture is one inch. The tools I used were a cut-off wheel, a drill, and a reciprocating saw.

aaextra 043.jpg

Cut or grind the square casting off the plug leaving some thread exposed beyond the face of the boiler fitting. Drill 4 small pilot holes.

aaextra 054.jpg

Enlarge the holes a little at a time in a sequence. Drill all the way through and hopefully you'll have an opening large enough for a saw blade to go through.

aaextra 052.jpg

Cut towards the edge but not into the steel threads. The hole is tapered. When you make contact with the steel, the screeching will warn you. It is only necessary to get within a 1/16" of the steel. Cut into quarters and then make an eighth cut to make it easier to punch that piece out. The rest of the pieces will then fall out.

aaextra 050.jpg

Punch the pieces out. Retrieve the pieces with a thin pencil magnet. It should take less than 10 minutes for each plug.

Or one can use a torch and heat up the plug and threads and use the correct size pipe wrench with a pipe on the handel for extra leverage and break it loose no chance of screwing up the threads with a saw blade :roll:
coal berner
 
Stoker Coal Boiler: 1986 Electric Furnace Man 520 DF
Stove/Furnace Make: Electric Furnace Man
Stove/Furnace Model: DF520

Re: Removing a rusted boiler plug

PostBy: Cap On: Tue Sep 08, 2009 9:15 pm

Was that a hollow cast plug or a solid forged plug?

But I like the approach in the absence of blasting the external area around the threads with a blue flame. Sometimes the square head becomes so rounded or buggered, you may not be able to use the Rigid.
Cap
 
Hand Fed Coal Boiler: Harman SF 250, domestic hot water loop, heat accumulator

Re: Removing a rusted boiler plug

PostBy: coal berner On: Tue Sep 08, 2009 9:25 pm

Cap wrote:Was that a hollow cast plug or a solid forged plug?

But I like the approach in the absence of blasting the external area around the threads with a blue flame. Sometimes the square head becomes so rounded or buggered, you may not be able to use the Rigid.

The torch works 99.9% of the time see it done on a weekly basis Cast plug on the return some of the older ones used forged plugs either way the torch works .
coal berner
 
Stoker Coal Boiler: 1986 Electric Furnace Man 520 DF
Stove/Furnace Make: Electric Furnace Man
Stove/Furnace Model: DF520

Re: Removing a rusted boiler plug

PostBy: Cap On: Tue Sep 08, 2009 10:07 pm

coal berner wrote:
Cap wrote:Was that a hollow cast plug or a solid forged plug?

But I like the approach in the absence of blasting the external area around the threads with a blue flame. Sometimes the square head becomes so rounded or buggered, you may not be able to use the Rigid.

The torch works 99.9% of the time see it done on a weekly basis Cast plug on the return some of the older ones used forged plugs either way the torch works .

What size welding tip do you use on your torch? Oxy/Mapp or Oxy Acetylene
Cap
 
Hand Fed Coal Boiler: Harman SF 250, domestic hot water loop, heat accumulator

Re: Removing a rusted boiler plug

PostBy: 009to090 On: Tue Sep 08, 2009 10:13 pm

Cap wrote: What size welding tip do you use on your torch? Oxy/Mapp or Oxy Acetylene

I wouldn't try cutting it out with a torch. I'd just heat it up. Let it cool down a little, and put the pipe wrench to it again.
009to090
 
Stoker Coal Boiler: EFM 520 HighBoy
Hot Air Coal Stoker Stove: DVC-500 x 2
Coal Size/Type: Anthracite Rice

Re: Removing a rusted boiler plug

PostBy: coal berner On: Tue Sep 08, 2009 10:47 pm

Cap wrote:
coal berner wrote:
Cap wrote:Was that a hollow cast plug or a solid forged plug?

But I like the approach in the absence of blasting the external area around the threads with a blue flame. Sometimes the square head becomes so rounded or buggered, you may not be able to use the Rigid.

The torch works 99.9% of the time see it done on a weekly basis Cast plug on the return some of the older ones used forged plugs either way the torch works .

What size welding tip do you use on your torch? Oxy/Mapp or Oxy Acetylene

You use the torch to heat it up not to cut it out once it is heated to red used the pipe wrench to turn it out
what is a welding torch I am talking about a cutting torch OXY & Acetylene you do not weld with a torch you heat & cut
with one You use a welder to weld with. I would hope you would know the differents between the two .
coal berner
 
Stoker Coal Boiler: 1986 Electric Furnace Man 520 DF
Stove/Furnace Make: Electric Furnace Man
Stove/Furnace Model: DF520

Re: Removing a rusted boiler plug

PostBy: Sting On: Tue Sep 08, 2009 11:02 pm

Excellent description for fixing a situation!
Sting
 
Other Heating: BurnHAM=NG-gas

Re: Removing a rusted boiler plug

PostBy: Cap On: Wed Sep 09, 2009 6:09 am

But I like the approach in the absence of blasting the external area around the threads with a blue flame. Sometimes the square head becomes so rounded or buggered, you may not be able to use the Rigid.[/quote]
The torch works 99.9% of the time see it done on a weekly basis Cast plug on the return some of the older ones used forged plugs either way the torch works .[/quote]
What size welding tip do you use on your torch? Oxy/Mapp or Oxy Acetylene[/quote]
You use the torch to heat it up not to cut it out once it is heated to red used the pipe wrench to turn it out
what is a welding torch I am talking about a cutting torch OXY & Acetylene you do not weld with a torch you heat & cut
with one You use a welder to weld with. I would hope you would know the differents between the two .[/quote]

JC, i got you!.. The heating tips on a torch are actually welding tips. Used in the old days before electric welding become so popular! I would use a #7 tip to heat the plug of that size.

Also you may not know, Mapp gas is a hotter fuel on the secondary flame. But Acetylene is hotter on the primary side of the flame which is what you use to cut.
Cap
 
Hand Fed Coal Boiler: Harman SF 250, domestic hot water loop, heat accumulator

Re: Removing a rusted boiler plug

PostBy: stoker-man On: Wed Sep 09, 2009 6:26 am

The plugs were the solid cast type with the square end on them. They wouldn't budge and with the extender on the pipe wrench, the ends broke right off.

I also have a torch set, but probably most homeowners do not.
stoker-man
 
Hand Fed Coal Boiler: 1981 efm wcb-24 in use 365 days a year
Coal Size/Type: Anthracite/Chestnut
Other Heating: Hearthstone wood stove

Re: Removing a rusted boiler plug

PostBy: Freddy On: Wed Sep 09, 2009 9:00 am

Nice tutorial. Thank you!
Freddy
 
Stoker Coal Boiler: Axeman Anderson 130 (pea)
Hot Air Coal Stoker Stove: Reading piece o' junk in the barn (rice)
Coal Size/Type: Pea size, Superior, deep mined

Re: Removing a rusted boiler plug

PostBy: coal berner On: Thu Sep 10, 2009 2:03 am

Cap wrote:But I like the approach in the absence of blasting the external area around the threads with a blue flame. Sometimes the square head becomes so rounded or buggered, you may not be able to use the Rigid.

The torch works 99.9% of the time see it done on a weekly basis Cast plug on the return some of the older ones used forged plugs either way the torch works .[/quote]
What size welding tip do you use on your torch? Oxy/Mapp or Oxy Acetylene[/quote]
You use the torch to heat it up not to cut it out once it is heated to red used the pipe wrench to turn it out
what is a welding torch I am talking about a cutting torch OXY & Acetylene you do not weld with a torch you heat & cut
with one You use a welder to weld with. I would hope you would know the differents between the two .[/quote]

JC, i got you!.. The heating tips on a torch are actually welding tips. Used in the old days before electric welding become so popular! I would use a #7 tip to heat the plug of that size.

Also you may not know, Mapp gas is a hotter fuel on the secondary flame. But Acetylene is hotter on the primary side of the flame which is what you use to cut.[/quote]

Yes I Know The Differents in Mapp & Acetylene Gas . Maybe they where called welding tips in the old days But Today in 2009 there called torch tips http://www.nationaltorch.com/tips.html
coal berner
 
Stoker Coal Boiler: 1986 Electric Furnace Man 520 DF
Stove/Furnace Make: Electric Furnace Man
Stove/Furnace Model: DF520

Re: Removing a rusted boiler plug

PostBy: coal berner On: Thu Sep 10, 2009 2:10 am

stoker-man wrote:The plugs were the solid cast type with the square end on them. They wouldn't budge and with the extender on the pipe wrench, the ends broke right off.

I also have a torch set, but probably most homeowners do not.


Yes you are probably right that most homeowners do not have a torch .
But on the other hand most home owners should not try this in there basement or anywhere else either .
They should get someone that knows what there doing to fix it .
Cutting into them threads with a saw blade or hitting them with a chisel or a punch is not a good thing either
alot more work & time to fix them.
coal berner
 
Stoker Coal Boiler: 1986 Electric Furnace Man 520 DF
Stove/Furnace Make: Electric Furnace Man
Stove/Furnace Model: DF520

Re: Removing a rusted boiler plug

PostBy: whistlenut On: Thu Sep 10, 2009 8:41 am

I have always used "the Fire Wrench" FIRST! If you bugger the square cap, it will be a long day with drill bit sharpening, breakage, sawzall time.....perhaps a screw-up. Heat it uniformly, have the pipe wrench adjusted properly and a couple of pipe extentions at hand. This sure saves some skin, and leaves time for other projects. Same is true on the nuts for hot water coils....don't even think that they will just spin off without soaking or heat. You only get one chance with them, and you don't need to play "Gorilla" with a 1/2" stud and nut. PS: chase the studs, and add some anti-seize before you reassemble anything on solid fuel appliances.

38 outside at 6AM......days getting shorter......fire them up boys!!! (and young ladies, sorry Lisa, forgot my manners)

:shock: :D 8-) :oops:
Last edited by whistlenut on Thu Sep 10, 2009 5:40 pm, edited 1 time in total.
whistlenut
 
Stoker Coal Boiler: AA130's,260's, AHS130&260's,EFM900,GJ&VanWert
Hand Fed Coal Boiler: Franks Boiler,Itasca415,NYer130,Van Wert
Hot Air Coal Stoker Furnace: Yellow Flame
Hot Air Coal Stoker Stove: Alaska-4,Keystoker-2,
Hand Fed Coal Stove: Alaska,Gibraltor,Keystone,Vc Vigilant 2
Hand Fed Coal Furnace: Van Wert, NYer's, Ford,Jensen.
Coal Size/Type: Rice,Buck,Pea,Nut&Stove
Other Heating: Oil HWBB