In a message dated 6/24/05 8:33:11 PM, blake@MATH.WUSTL.EDU writes:

<< Maybe you can get in with a drill and an easy out? >>

I've used Easy-Outs more than I care to think about.  Whenever I use them, I
always find myself clenching my teeth from the fear of them breaking and
snapping off an Easy-Out means finding a shop with an EDM setup.  The biggest
mistake in using them is to disregard the manufacturer's recommendations for the
size to use and the size of the pilot hole.  The style of Easy-Out which I
distrust the most is the helix type and I have good ones, at that, made by Morse
and National.  I much prefer the square section style which seem to be tougher.
Having said all that, I think in this case you would do better to drill out
the old stud and install a thread insert or tap the hole to the next larger
size.  The insert is the best way to go because a bastard sized fastener in an
assembly can cause confusion (and even calamity) during work done in the future.

George