Frost Plug Removal and Iron worm

["Mike Hopton" <mike@genesis-microchip.on.ca>]

     Any suggestions on an easy way to remove and replace the frost plugs on an 
     I5 turbo engine block? The obvious way seems to be to drill them out but I 
     want to minimise the shards of metal in the water ways. 
     
     The block in question has quite a bit of rust; any suggestions for rust 
     removal? My current technique uses a hammer and screwdriver to remove the 
     worst, then a wire brush and then some product like Naval Jelly to remove 
     the brown dust. I experimented with CLR (drain cleaner) on the weekend and 
     was fairly impressed with results, this required complete immersion of the 
     parts to be cleaned - however I don't think my SO will be to impressed if I 
     dunk the engine in the bathtub - anyone tried this at home... 
     
     Any recommendations on engine enamels to paint the block, the Canadian tyre 
     manifold paint I used on the outside of the valve cover does not resist 
     petrol (gas).
     
     Thanks and regards, Mike