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The fitting was definitely rubber, the corrosion was in the galvanized pipe. It appears the damage would have had to been pretty severe for this to have happened, i.e. cut all the way through the epoxy coating and galvanizing. I'm having a trusted gas plumber come by to quote it. The heater...

and fixing it.. ugh.. it's got a 1.5" IPS going into the main 2" line... the 1.5" risers are 40+ days to order. I can get a 1" or 2" quick. any advise on splicing IPS? use PVC glue?

I am guessing, and can only guess, is when it was installed the factory fitting was cut and it ensued to corrode over the years. Here is the outside pic before I pulled it apart. It surely was leaking gas. Odd thing was when I ran compressed air I was getting flow going both ways, but guessing...

Mystery solved. Once I got it completely dug out the riser came apart from the IPS without much trouble as it was corroded all way through. There is the problem!

About 15 years. We scoped it from the other way and it was yellow pipe, so guessing I'm going to find the iron riser transitions to plastic fairly shallow.

Haha.. Well he's 18 so maybe not technically a boy.. shipping off to the Navy in 4 weeks! Going to dig it up in the morning, I'll post what I find. This was the last thing I suspected. I should have listened to JamesW earlier!

I rented a miniflex cam that can scope down to a 3/4" line with 100 feet of cable. I started at heater and and right there at the riser it was completely shut off with corrosion, maybe a 1/4" opening but camera could not make it through. I went to meter side and ran scope 110 ft into pipe and...

Looks time to replace the bloody thing.. It's 1.5" and I need about a 100ft of video scope to reliabily see what's going on. The ones on Amazon are 50ft and don't think those types can make hard 90's. THanks all for the help. now time to return all these darned parts!

Used a leaf blower x 2 (gas and high powered electric) just too much restriction to be helpful. Then used a shop vac on either end. Had flow but hard to say if it was good flow as the distance is so long. I had 0 evidence of water. Calling that guy back out tomorrow. Clearly an issue in the...

Of course.. I have a high powered electric blower going to mate up and try today. After this it's getting prices for line replacement. It's not acting like a kinked line so hopeful this will push water out.

looks like my leaf blower at 400CFM will be the try for tomorrow!

I'm up for suggestions! Any thoughts on what to try?

about 200 ft.. it's opposite corner of a 1/2 acre property basically. I need to run that last check of checking the wc at the meter when the heater fires. The guy I had out claimed "flow was good" out of the meter but he didn't run that check. Everything else works fine except for the...

Ran for about 4 hours.. no signs of water. Had decent airflow on the other end as well. When I put it all back together and recharged the gas line same result as the video. Small smell of gas and failed ignition. ugh

yeh no trap at all. That tap you see goes to gas lights by the pool. They were very low flame as well compared to what they had been. The water theory seemed feasible when adding that into the equation. The compressor is a rented dewalt from home depot.

Thank you Chris.. I have a compressor running now starting at the heater going back towards meter.. Getting air flow for sure. I put a valve on the opposite end of compressor and have it half closed or so to create some velocity. No obvious signs of water but going to let it run for 4-5 hours...

I can only assume yes because it's been here for 15 years. Good call on the valve as well and I'll check that. Although it's never been operated since I have lived here.

Ok, checked at the meter and did a flow test. Was good. I think the plumber did the purge wrong. He pushed air from the downhill side instead of at the heater which is higher. Going to try again tomorrow.

There are some photos. The 1.5" plastic on the right is the feed out to the heater. We were able to put 10lbs on the line and no leaks.

No luck on water in the line. We blew it out for an hour and not a drop. No change in the operation of heater. Guessing that maybe a tree wrapped roots around line somewhere? Lost on this one!

Well here it is and James was right. It was a gas pressure issue. It sits at 10" WC and when the valve open goes to 0. We had a ton of rain and we have gas lights that collect all that rain. When the gas lights are turned on water gets into the line and builds up. Getting it blown out...

Swapped out the valve. No change. Exact same behavior! So far I have a new Fenwal, Igniter, gas valve. James you said the blower didn't sound right. Any further thoughts on that?

Much appreciated. I'll followup next weekend with how it went!

That's what I'm thinking.. If the valve doesn't work then I'll take the blower apart.