Exhaust manifold drain plugs

[yeahbuoy]

Anyone have tips for successfully removing broken exhaust manifold drain plugs?

We’ve had a great season while also resolving the many gremlins in our new to us 2005 SV-211 (saved our sanity this summer during COVID distancing). Now finding the next set of gremlins while winterizing. Good so far, but found both exhaust manifold plugs are missing half of the 1/2” socket, so I have a challenge to remove them.

what’s my next step toward repairing this situation?

Thanks!

[NautiqueJeff]

Can you post a picture of the plugs? I can't quite picture how they have broken.

[yeahbuoy]

Pics for reference...

[NautiqueJeff]

Wow. I haven't personally had any break on me like that before.

I guess the only thing to do is soak them in some sort of penetrating oil (or a mix of ATF and acetone) for a few days and get a grip on them with some vice grips and try again. If that doesn't work, you might be able to heat the manifold with a torch to get them out.

If all else fails, new manifolds aren't that expensive.

[LakesideRec]

They are likely mild steel or something even softer. Drill a round hole in the middle (careful not to drill through the other side of the manifold) and then use an easy-out tool like this:

https://www.youtube.com/watch?v=SMrDYJvY0Ts

[yeahbuoy]

Thanks, gents. Already started hitting them with penetrating oil. I plan to repeat for a couple of days, then try to work them out similar to what NautiqueJeff suggested. In the meantime, I’ll acquire a big easy-out in case that is needed.

Are the brass replacements best?

[NautiqueJeff]

I use the brass ones and have never had a problem.

[Jonny Quest]

+1 for using brass instead of steel.

JQ

[SilentSeven]

Or get these...

https://skidim.com/easy-drain-exhaust-manifold.html

I have them on my manifolds and would never go back to regular plugs. Skidim used to have a full engine kit but seems to be no longer. I'm sure with a bit of looking you can locate the bits and make your own.

[Jonny Quest]

I like a brass bushing that is 3/4” X 3/8” and brass plug. The brass plug can be removed from the bushing to drain water. The bushing also allows for a wire or probe to be inserted to clean out debris or rust flakes that can clog up the drain petcock.

JQ

[xlwater01]

I’ve winterized a lot of different nautiques for friends and the only manifold drain plugs I’ve ever seen from the factory are the brass ones that accept a 1 1/16 inch wrench or so. 90’s - 2007 era boats (gt40/Excalibur) are what I’ve worked on and they all have the brass plugs.

Just curious Why does the OP’s 2005 211 have steel plugs on the manifold? Or did these maybe get replaced at some point?


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[zmnypit]

weld the extension to whats left of the plug? I've had to do this on bolts in jetskis before. If I cant tig weld it I make sure to put a welding blanket down and use the mig. Otherwise may be easier to remove the manifold and repair outside the boat.