Hi Craig
I am not sure if this suggestion made to the list so here it is  again;

I use a small  punch ( a Snap -On in my case )  and "break"  the hardened
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.

This job is very do-able in the car and you don't have to put an engine in
all you need is a little patience.
( which it sounds like you have )

Go to Home Depot and buy a Stanley brand nail set (the smallest tip  possible
) than just slowly chip away at the drill bit like you are carving a  fine
piece of Carrera marble and you will prevail !
Make sure you wear eye protection those little pieces of drill can really
fly.

I wish I was closer to help out but I am there in spirit!

I too have this passion for my Vanagon and the smile that follows. I don't
have much money to make mine pretty so it looks pretty bad but It is pretty
solid mechanically after tinkering with it for a few years.

I would be glad to help over the phone or Email  and I still have the
complete 1.9 exhaust .

Jeff  E.
Atlanta , Ga.
678-549-8430
87' Westy "weekender"

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