Removing Broken Plastic Elbow Fitting From Engine Block

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Author Topic:   Removing Broken Plastic Elbow Fitting From Engine Block

JLL posted 09-05-2009 12:09 PM ET (US)
I have a 1980 Montauk with same vintage 100 HP Johnson outboard. Both original and running strong. While cleaning out the [aspirator] tubing, the 90-degree elbow which is made out of nylon cracked off the engine block. It broke off flush with the block. I now have part of the elbow remaining in the block and cannot remove it. I don't want to damage the threads. Does anyone have a good idea as to how best to remove this so I can install the new elbow? I was thinking of possibly applying heat with a propane torch to melt or burn away the nylon.
Thanks,
Jim
contender posted 09-05-2009 01:39 PM ET (US)
If it is just plactic try an easy out, Or try to collapse the plastic and pull it out with a thin nose. Also try a pick to collapse the plastic or nylon part and then pull it out. Not hard just going to take some time and patience. You could also try a small punch sharpen to a chisel on one side and carefully hammer the plastic to turn it out or collapse it. Good luck
jimh posted 09-05-2009 02:17 PM ET (US)
Use a heat gun to warm up the engine block and fitting. Try and easy-out remover. Or, drill it out carefully, assuming you can easily reach the fitting with a hand drill.

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Author	Topic: Removing Broken Plastic Elbow Fitting From Engine Block
JLL	posted 09-05-2009 12:09 PM ET (US) I have a 1980 Montauk with same vintage 100 HP Johnson outboard. Both original and running strong. While cleaning out the [aspirator] tubing, the 90-degree elbow which is made out of nylon cracked off the engine block. It broke off flush with the block. I now have part of the elbow remaining in the block and cannot remove it. I don't want to damage the threads. Does anyone have a good idea as to how best to remove this so I can install the new elbow? I was thinking of possibly applying heat with a propane torch to melt or burn away the nylon. Thanks, Jim
contender	posted 09-05-2009 01:39 PM ET (US) If it is just plactic try an easy out, Or try to collapse the plastic and pull it out with a thin nose. Also try a pick to collapse the plastic or nylon part and then pull it out. Not hard just going to take some time and patience. You could also try a small punch sharpen to a chisel on one side and carefully hammer the plastic to turn it out or collapse it. Good luck
jimh	posted 09-05-2009 02:17 PM ET (US) Use a heat gun to warm up the engine block and fitting. Try and easy-out remover. Or, drill it out carefully, assuming you can easily reach the fitting with a hand drill.