Just couldnt catch a break today. Started with this:
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Left me with about 3-4 threads showing. The red tape on the other bolt represents about how much was in the manifold. If I had a welder Id just thread a nut on and put a weld and hopefully pull it out. I dont, so I was able to get my grinder in there and notch it. Tried to jam a large screwdriver in the but it just broke the tip of it off:
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Pretty much only left me with one option....drill it out. Started by grinding it down as level as I could:
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Hit it a few times with a punch and started drilling. Started with 1/8th and worked up...
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After taking my time, constant steady speed and I had a friend keep the bit-bolt lubed. Then we tapped it and bam.....:
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After reading several articles on this I wanted to avoid using an extractor if at all possible. From what I read many of them break and then your literally screwed trying to drill that out.
My trick: Left Handed bits and a reverse drill and patience.