In a message dated 7/13/2007 9:39:09 P.M. Eastern Daylight Time,
phishman068@GMAIL.COM writes:

So today  my day at work started as any would (except discovering the trash
truck put  a sizeable dent in the nose of the vanagon......which will be
repaired free  of charge), and the mecahnics at my work started working on my
vanagon. I  popped in from time to time to check the progress. The goal was
to replace  the manifold gasket at cylinder 1, so the manifold had to come
off as the  studs were damaged. Of the 4 bolts that connected to the heads
and 2 that  connected to the collection pipe (1.9L) The collection pipe bolts
came  right off, and 3 of the head nuts. One was not so lucky. It snapped and
the  mechanic welded a nut to the stud and started backing it out.....it  was
working really well....till it broke the stud halfway inside the  head.
So......out comes the tungsten carbide drill bits.......a very  accurate and
perfectly executed drilling went horribly wrong when the bit  broke off flush
with the head. "You cant drill out a drill bit" boss  mechanic said.....so
over the course of the weekend the entire staff is  trying to figure out how
to fix this without removing the head (or even if  the head comes
off.....what do you do?)

Sudgestions so far include  "Burn it out" though i dont know how, "Stronger
Drill Bits" which are on  order but have low expectations, and "replace the
head".

Any ideas  are greatly appreciated!!!!!!

-Craig
'85GL (which isnt having its  best day)

I use a small  punch ( a Snap -On in my case )  and "break" the  brittle
drill bit out a little at a time.

Than I would use a Left handed drill bit from there.

I would probably do it in the vehicle but obviously it is easier with it
out.

Good luck!

Jeff  E.
Atlanta , Ga.
87' Westy "weekender"

************************************** Get a sneak peak of the all-new AOL at
http://discover.aol.com/memed/aolcom30tour