vent liner stuck!

[Black Jaque Janaviac]

On one of my flintlocks I have a White Lightning liner that is stuck.  It has been in for 15 years.  So far I've tried using:
easy out
propane torch
drizzling penetrating oil in/around it
letting oil sit like that for 48 hrs

no budge.

Now the hole is pretty big so I filed it square.  Next I am off to store to get key stock or small square driver to fit.

I am running out of options.

[Bob Roller]

Find out what thread is used if possible and get a drill bit for that particular thread.
I THINK some of the Chambers vent liners use an Xtra fine thread like 3/8x32 and
you might have to call Jim or Barbie to find out the recommended drill size.

Bob Roller

[David Rase]

You  might have to keep drilling the touch hole liner until you can see evidence of threads.  Once you see the threads you can use a scribe to pick away the remaining liner threads.  If you get lucky the remaining thread remnant will come out in a spiral like a cork screw.  If not, you just keep picking.  You can then chase the threads and install a new liner.
David

[Scota4570]

Maybe get it really hot , like you are getting some heat colors.  Then sleectively quench the actual liner with aerisol electronics duster held inverted.    That should shrink the liner enough to bust it loose.  The easy out should work then. 

Do not heat the barrel red hot then flash freeze it!   

Are you sure the breech plug is not causing you problems? If the installer cut into the vent liner with the breech plug tap it would be mechanically locked. 

[Black Jaque Janaviac]

the liner was installed after the breach plug.
ugh.
I may have a tough time drilling it out.  the hole is not perfectly centered.

[Pennsylvania Dutchman]

If you are using a spiral flute ez-out and the hole in the liner is fairly large as to make what's left of the liner thin walled, the ez-out will swell the liner as you turn it and lock it in tighter instead of removing it. You can get tapered square ez-outs at an auto parts store. You just tap them in snug with a hammer and turn them out.
Mark

[Black Jaque Janaviac]

Thanks for all the advice guys!  Keep it coming.

I had read about the easy out actually making things worse.  That's why I tried the squaring out the hole and using a square driver.  The square driver just stripped the hole round again. 

I may try the auto-parts store square easy out - that might help. 

It is a 3/8" White lightning liner.  So I don't think I have the option of drilling out and tapping for a larger liner.  If I drill it out I may have to do as David Rase suggests.  However, I just know Ol' Murphy's law is going to kick in and I will drill and drill and not see any threads. . .

[Cuboodle]

Get a small jar mix 50/50 transmission fluid and acetone shake the bejezzus out of it apply as penetrating oil keep it well soaked for several hrs it will come right out.

[Eric Krewson]

The liner may be jammed against the breech plug. I would pull the breech plug and see what is going on.

[SingleMalt]

The liner may be jammed against the breech plug. I would pull the breech plug and see what is going on.

Yup.  That'll tell the tale.  Since the liner is so thin, the plug should be able to get past it, if it's binding it.

[Eric Krewson]

You can buy one of those $12 bore cameras off eBay and take peek as well.

I found out one of my rifles had the vent liner threaded into the breech plug with one of those cameras.

[Black Jaque Janaviac]

They always say to never remove the breech plug.  I am guessing that since this is a gun-builders forum the level of expertise is such that this advice is not unusual.

So, I am guessing the reason they advice never to remove the breech plug is because to put it back requires threading it all the way down to bottom out, and aligning the tang with the top flat "just so".  My barrel already has a witness mark across the barrel and bottom part of breech plug. 

Is there some other tricks to removing/reinstalling a breech plug?

Would I be better off drilling it out until it is thin enough to pick out the remaining metal?

[flehto]

Remove the breech plug....and see what the problem is. You'll have to do it when installing the new liner.....Fred

[Pennsylvania Dutchman]

Black Jack, Here is the ez-outs that I mentioned in my post that I use. Proto #9500A or Cal-Van #441 They are both made by Proto and are identical except for the marking on the pouch. It is a set of 5 ez-outs. I bought mine at my local auto parts store.
Mark

[Ky-Flinter]

They always say to never remove the breech plug. 

Who is "they"?  If "they" is CVA, Thompson Center, Traditions, Cabela's etc., they advise this because of the design of their breeches.  If you have one of their guns, follow their advice.

Since you say the barrel and breech plug lug has a witness mark, I assume you have a barrel from Rice, Colerain, Rayl, Burton, Getz or other customer barrel maker.  You will need a good vise and a big adjustable wrench.  Search on "breech plug removal" for many posts on the topic.

If you end up having to drill out the liner, you will want the breech plug out of the way.  If the hole is off center, use a file or dremel to enlarge the hole in the direction to center up the hole, then drill with a small bit, then the next size bit, etc. until you get close to the threads, then pick them out.  If you have access to left handed drill bits you may be pleasantly surprised.  Sometimes the LH bit will back the liner out for you.

-Ron

[T*O*F]

So far, no one has addressed your real problem.  They are just speculating.  Simple mechanical problems are solved before any work actually commences.  You need to know what you are dealing with first.  Physically examining a liner's construction will give you a clue.

If you truly have a White Lightning liner, then it has a tapered shoulder on it and is screwed up tight in a countersunk hole in the barrel.  It's a tight, friction fit to start with and after 15 years is probably rusted/corroded in place.  You have to run a countersink into the touch hole and remove this shoulder.  Then you can probably use an EZ out to remove the remaining threads.

Amateur gunsmiths, like shade tree mechanics, soon discover that problems are not solved by committee.

[Ky-Flinter]

Looks like none of us need to offer any more ideas, as Dave has stated exactly what needs to be done.

-Ron

[Steve-In]

I would NOT drill out until the threads are visible.  There is little enough threads as they are without removing more. 
I agree with TOF that the chamfer is probably binding up. 
Worse case is the liner was over torqued when installed and the threads are messed up.  Add some locktite to it and you have a challenge.  Not knowing what tools you have available hurts too.

[Acer Saccharum]

If it's a 1/4" or 5/16" there may be the option of using a larger liner, if your flats will take the larger diameter.

[bob in the woods]

It's a 3/8th liner

[Black Jaque Janaviac]

HA!

I took it to a friend's shop.  He grabbed an easy-out, chucked it up in an impact driver and had it out in less time than it took me to type this! 

[TMerkley]

EVEN BETTER!!!