Hi Jim thanks for the info
problem is i have it on my lift in the pole barn motor is still in the
van. if the head was off i would just chuck it up in the drill press
and drill it out. i really really really dont want to pull the head for
a bogus studi could possibly drill it out with an angle drill and if i
take out to much put in a heli coil. i have a mig and can tack a stud
or a nut to it. maybe thread the 2.5 threads on and fill the rest of
the nut with mig wire. i dont know how long the bolt is. this is the
2nd exhaust for this bus and the head of the bolt was originally a 13
and it was rusted to the size of a 11mm and it fit perfect. enough bite
to snap the stud. thanks for your help. any other suggestions?? c-ya
Jonce

>If it's where you can lock the head up in a drill press, why don't you
>find the center of the bolt and step drill it till you get it close
>enough to the inside thread diameter to chase it out with a tap. You'll
>need a bottoming tap too unless the hole is a good bit deeper than the
>bolt.
>
>That heat deal doesn't work so well with aluminum and steel. Once I had
>the same thing happen to a 911 head, and ended up having another bolt
>welded onto the exposed threads of the broken one. but if I had it to
>do again I'd drill it out.
>
>Jim
>
>On Jun 29, 2004, at 8:58 PM, Jonce Fancher wrote:
>
>> Hi all
>> im in the process of removing the swiss cheese exhaust system from my
>> 84 7 passanger van with only 20 k miles. so after using a chisle and
>> center punch to cu the nuts off of 2 studs and thinking im golden the
>> last bolt after soaking for 2 weeks in PB blast snapped off2 threads
>> exposed from the head. so now i have a forzen partial bolt in the head
>> of the # 1 cylinder upper. the question is what should i do to remove
>> it?? Mig something to it and beat on it with the heat from migging and
>> the extra grip that i added i just turn it out right?? what ive done is
>> wire brushed it to remove all corrosion and dirt then soaked with more
>> PB Blast waiting for me to come up with a grand idea to remove it. any
>> suggestions?  or FAQ pages? thanks Jonce
>>