Any tried and true method of removal?

[rockfla]

Originally Posted by Model51

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.

Thanks Dave
The current plan is to remove the intake so I can get a better angle on it and not contaminate anything else and do just as you have described…..I can’t think of any other way!!!