bad deal, center punch, reverse drill and tap if needed. if you cant use a right angle drill, pull it. welding will not work without also heating the head with a rosebud before you try to turn it. its to much heat on that cast.
been there, done that, used one wrong bolt on a 302 intake. it snapped, had to remove the intake. a good welder may be able to weld a stud in place, but it needs heat treated after or it wont be strong enough.
2-4 hrs to pull the engine and then its on the bench, good time to reseal crank, pan, new timing chain, and some chevy orange
Pull the engine. There is no other way.
It's probably easier to pull the head off and drill the broken manifold stud out on the bench then it would be to pull the entire engine. (no easy fix for that conundrum)
Sadly it needs removing ..lots of work but will blow if left.
Pull the head, and have the bolt welded out. I don't remember EVER having an EZ out work for me. If you weld a washer to the bolt, then weld a nut to the washer, the bolt will come out easily, every time, most times you can turn it out with your fingers.
I pretty much know the answer, but just want to see if someone has an idea/tip or something.
I own an 86 El Camino. I did an engine swap and took out the small block 305. Then I put in a 402(396) into my El Camino. My exhaust broke in a few spots. When it broke it snapped the header bolt closest to the firewall. As it sits now it is pretty much impossible to extract the broken bolt unless you pull half the engine out to even get something like an ez out to it.
So my question is there another way you can seal a header to the block that does not require a bolt?
