SUGGESTIONS PLEASE - ALUMINUM SEIZED TO ALUMINUM

[NOOMA]

trying to remove the aluminum fitting for the pickup tube from an aluminum gas tank. The tank is 44 years old and appears to be in good solid shape but the fitting is frozen in tight. Reefing on it as hard as I could, would not budge. Not wanting to break the weld holding the threaded insert, has anyone got a solution for freeing it up before going to brute force. Tank is 1/4 full so heat (torch) is out.
Thanks in advance, Ted

 

[ship happens]

You might have to drill it out and tap if it doesn't come loose. The fitting will most likely break before the welded bung. If it were me I would just drill and tap it. If the threads come apart while getting it out then you got to go up a size and that's more of a hassle

 

[seachicken]

You might have to drill it out and tap if it doesn't come loose. The fitting will most likely break before the welded bung. If it were me I would just drill and tap it. If the threads come apart while getting it out then you got to go up a size and that's more of a hassle

If you drill it pack your drill bit with grease frequently to catch the swarf. The fitting should hold the drill bit on center somewhat and hopefully you'll just have to pick out the threads at the end. Start small and work your way up in drill size.

 

[Offshore]

Can you post a picture?

 

[ship happens]

Because it's an FIP bung I doubt you can drill out and pick the old threads. Because of the taper. Not only that but when aluminum corrodes to itself its almost impossible to release the 2 parts. It's probly 3/8 NPT

 

[NOOMA]

Thanks for the come backs. I'm think of doing some chemical approaches before drilling - maybe brake clean, Sea Foam -Green Creep, dry ice, Ship to Shore, and maybe Tabasco sauce. Then a gentle hit with the impact gun. But before that need to find a 3/4 by 3/4 square socket.
Thanks again

 

[Dorman Point]

A very effective penetrating solution (I have found, anyway) is 50/50 ATF and acetone.

 

[Max123]

Impact tools are usually the tool of frustration/last resort that just ends up snapping off the head and forcing you to drill it out. I'd recommend slow/high torque with a breaker bar and lots of penetrating lube. Usually you only see breaker bars being used on bigger/steel fasteners with 1/2" socket fittings but I've found tons of success using a 1/4" or 3/8" ratchet, and slipping a small pipe extension over the handle so you get a 24" breaker bar. It just totally changes the amount of slow/consistent force you can apply without messing up the fastener.

 

[NOOMA]

SUCCESS - none of the local tool stores carry a 3/4 by 3/4 square socket but with a little help from my heavy equipment mechanic and a bit from Max123's post made it work. Sprayed the fitting with Green Creep then used my 3/4" rachet. Turned a socket upside down to fit over the 3/4" fitting and with the normal socket end that fitted the racket drive. With slow but steady pressure, the 20" handle on the racket broke it free.
Thanks again for the support. Ted

 

[Rain City]

SUCCESS - none of the local tool stores carry a 3/4 by 3/4 square socket but with a little help from my heavy equipment mechanic and a bit from Max123's post made it work. Sprayed the fitting with Green Creep then used my 3/4" rachet. Turned a socket upside down to fit over the 3/4" fitting and with the normal socket end that fitted the racket drive. With slow but steady pressure, the 20" handle on the racket broke it free.
Thanks again for the support. Ted

So glad I followed along. Great entertainment. Congrats!