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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