What is the best material for the water outlet fitting and the various pipe plugs to use in an aluminum intake? What is a good sealer that will not allow galling?
"water outlet fitting"....are you talking the thermostat housing? I'd go with aluminum. My block and heads are aluminum, so is my oem thermostat housing, but everything else oem is steel for the pipes and plugs. I use Loc***e marine grade anti-seize compound, and I strongly suggest adding a sacrificial anode to your radiator, as well as using distilled water when you mix the coolant.
If you are using rubber hose & clamps most fittings will be Br***. Temperature gauge will also be Br***. Most manifolds only have three water outlets. To plug the last hole I used a Chrome pipe plug from a Hot Rod Parts Store. Put them all in using Teflon Paste. Good Luck!
I totally agree with Texas57 get the sacrificial anode, this is also a good anti-seize Permatex 81343 most Autozones will have it it is aluminum and copper based and will withstand 1600 degrees I also use it on header and exhaust bolts