Rust is very tough and hard. It is causing your issue. Wire brushing is not going to touch the rust. A cone shaped stone on a die grinder will. Just remove enough rust to see cast iron, do not hog it out. It is necessary to realize that it is already rusted through the place where the threads should be. The result will be threads lower in the manifold. No problem if the pipe you use can be trimmed shorter in the threads to keep it bigger than full tapered threads. Cutting off a little (1/4 to 3/8 of the top of the manifold will make it closer to the proper size where the threads will go. It is important to use a great thread cutting oil (Tap Magic is the best I have ever found). A system to firmly hold the centering hole of the square end of the tap directly over the center of the hole, and a means to put about 100 pounds of down force on it will help. As will using a real tap wrench with equal force applied to rotate the tap, (a crescent wrench pulls sideways as well as turns) Best of luck, Jim
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Today's Featured Article - Fordson Model N: Field Service Operations and Lubrication - by Anthony West. The daily or weekly servicing of any vehicle is of the utmost importance, and in days gone by when our favorite tractors were doing an important and Commercially vital job on the farm, these service operations would make a major difference to the running costs and economy of the farm. This being so, it surprises me to see how many enthusiasts attending rallies, shows etc, seem to be unaware of the importance of this constant attention. Possibly the modern machine with its 6,000 mile or even once
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