Rust is very tough and hard. It is causing your issue. Wire brushing is not going to touch the rust. A cone shaped stone on a die grinder will. Just remove enough rust to see cast iron, do not hog it out. It is necessary to realize that it is already rusted through the place where the threads should be. The result will be threads lower in the manifold. No problem if the pipe you use can be trimmed shorter in the threads to keep it bigger than full tapered threads. Cutting off a little (1/4 to 3/8 of the top of the manifold will make it closer to the proper size where the threads will go. It is important to use a great thread cutting oil (Tap Magic is the best I have ever found). A system to firmly hold the centering hole of the square end of the tap directly over the center of the hole, and a means to put about 100 pounds of down force on it will help. As will using a real tap wrench with equal force applied to rotate the tap, (a crescent wrench pulls sideways as well as turns) Best of luck, Jim
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Today's Featured Article - Women and Tractors - Tractor Engine Repair - by Teri Burkholder. One of the great things about working on a tractor engine with your other half is that you know what he is thinking of at all times and can anticipate his every move and his next thought of what he will do. With Ben, anyway, I can tell! He'll be busy working and I’m handing him tools and he says, "give me that..." and I’ve already got it in his hand or "hand me that....."and I’ve got the portable light right where he needed it placed to see. "Run in the house and get me a...."as I open th
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