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Model51 · 02-02-2025, 04:54 PM

I had the same problem with cast iron valve covers. I ended up carefully drilling it out incrementally increasing drill bit diameter until I was afraid of hitting the threads or the bottom seat in the valve cover. Then I used a pick to pry the remaining brass bits out (along with some choice words which are inappropriate to mention here). Obviously I had the valve cover on the bench and not on the engine.

I think the issue of dissimilar metals is the culprit. Looks like you have a harder challenge with soft aluminum.

02-02-2025, 04:54 PM	#2
Model51 Senior Member Join Date: May 2010 Location: Fairfax Station, VA Posts: 934	Re: Any tried and true method of removal? I had the same problem with cast iron valve covers. I ended up carefully drilling it out incrementally increasing drill bit diameter until I was afraid of hitting the threads or the bottom seat in the valve cover. Then I used a pick to pry the remaining brass bits out (along with some choice words which are inappropriate to mention here). Obviously I had the valve cover on the bench and not on the engine. I think the issue of dissimilar metals is the culprit. Looks like you have a harder challenge with soft aluminum. __________________ 1935 157" 1 1/2 ton stake truck undergoing full original restoration 1936 131 1/2" panel truck rescue preservation Author of the 1935-1936 Ford Model 51 V8 Truck book published by the Early Ford V8 Club of America