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[Smokeless]

I'm sure this has happened to many mechanics and boiler repair people. A broken off cast iron 1 1/4 pipe plug. I will show you an easy way to get it out. I hope. LYAO  if I dont. that's laugh your ass off   I am changing my flow direction from OWB to my oil boiler inside.  I have a lack of flow issue and I am sick of dealing with it over the past 12 years. I would deal with it with my wood stove Inside cellar. Now I have a G-200  with all kinds of hot water that I need to get inside. So I need to get this plug out it was a 1" square now it's broken off. Uggghhh.

[coolidge]

Is there still enough to get a wrench or vice grips on. A lot of heat, glowing red and it should spin out.

[Sloppy_Snood]

1.  Drill a hole in in the center of the break
2.  REVERSE thread tap it
3.  Screw in appropriate REVERSE THREADED bolt (or use a die to reverse thread a sacrificial piece of high carbon steel rod; square the end of the rod).
4.  Add penetrating oil to threads (below for the world's best penetrating oil)
5.  Screw COUNTERCLOCKWISE to remove rod and plug.

If you soak the threaded junction with a 1:1 mixture of acetone to any cheap Automatic transmission, you will have a much easier time removing the seized plug.  DO NOT USE OR HAVE ANY IGNITION SOURCE around, near, or on the plug (as this is EXTREMABLY FLAMMABLE).

[mlappin]

I you don’t have access to heat or left handed taps there is another way but you have to be careful.

Drill the center out of the broken plug to largest size you have readily available, take a sawzall and cut from the center almost to the outer threads, do this 6-10 times, take a hammer and punch and knock loose the cut pieces.

[Smokeless]

MLappin your the man that is correct brother. You must of been  in the same predicament ??There is nothing protruding out. This is the easiest and fastest way to remove cast iron. I bought a dewalt oscillating saber saw. That cuts very fast threw cast. I already had heat on it and around it to help lossen the sealant before I broke it off. Cast drills like butter. So I will let you know tomorrow how long it takes me. And put up some more picks. Thanks

[hondaracer2oo4]

A cold chisel will handle that easy. The cast fails quickly when assaulted with a chisel and a BFH( Big F$%$#@ Hammer). Just take the cold chisel to the exposed threads striking towards the center of the pipe. That should break the end of the plug clear off after a few hits. Then take the chisel to the threads again. Now that the plug has no support from the end cap it will easily fold inward. Once the threads start to fold inward like a tent it is game over for the plug, a couple more hits and the threaded portion will fall right out.

[slimjim]

Great posts guys for a real pain in the butt problem!

[Smokeless]

Finally done. Got it out and hole tapped.  Don't forget to put a bushing over the drill bit. Prevents drill from going in to deep and hitting heat exchanger coil. Took a total of  90 minutes. Now my OWB hot water will poor onto that HX for the domestic HW. See it in pic.

[Sloppy_Snood]

Good job smokeless.  But it looks like your sawzall blade got into the threading.   

How are you going to seal it now? 

[hondaracer2oo4]

Looks like my typical method of folding in the threads would not have worked on this size plug. It is so small it was basically a solid piece of cast. I think I would have used the rosebud and gave it a good heating and then used a cold chisel on the side of the threads to spin it out.

[mlappin]

Good job smokeless.  But it looks like your sawzall blade got into the threading.   

How are you going to seal it now? 

Long as you don’t cut past the threads in the bung usually it will still seal.

Might have to do the paste on the male threads, a layer of tape then another of paste.

[Smokeless]

All is good I used liquid Teflon and tape. It sealed. No leaks. So far. I did cut into female threads more than I wanted to. Sucks getting old n can't see crap. I heard the girl friend say OOOHHH crap THATS HOTT. WHEN SHE WAS DOING DISHES. I now have a 20 degree difference going and coming from boiler.  I also put on a grundfos 15-55 Alfa just to play with and get familiar with in case my customers have any questions on it. Tells me the gpm and watts using. My manual gauges are totally different readings from my laser heat gun?  Best regards to all. Happy new year!!!