The small hole will act as a guide, in the hole with the broken EZ out in it you want to use a right hand drill bit, it will eventually loosen, once it is out go to left hand bits. Carefully grind any protruding bolt or tooling flush with a dremel, bolt the plate with the slugs using the smaller slugs and place the long one over the broken bolt by switching the location of the slugs any of the holes can be drilled through the longer one. of these slugs is the size you will drill in the jig plate halfway through.
Depending on how many bolts the manifold uses for an example we will use 6, drill 5 of these through the middle with the original bolt hole size and the 1" long with a M3 or M4 hole. 10 for M6 or 12mm for M8 bolts and cut it into 1/4" and one 1" lengths (you may find washers you can use for the 1/4" ones. once you have the holes drilled for the correct size bolts eg M6-8 drill the holes in the jig half way though only with a larger size drill, more on that later. You need to make a small drilling jig, no need to buy one use your manifold as a template on 3/8 flat stock (aluminum is fine) with a drill press. Not a very useful comment I grant you at this point, that horse is out of the barn but keep it in mind. Rule number 27 (I just made that up), never try to remove a bolt that broke off due to corrosion with an EZ out, broke off going in yes, no problem. Broke the EZ out off in the drilled hole. Any chance of getting one of the maniifold c-clamps on there? It would still leak eventually, the lack of clamp force would allow the gasket to blow out. Thoughts from the shadetree and pro-wrenchers, please? Sure, all of the other studs and bolts would be in place to clamp down the manifold, except for in the one area where the two broken ones are. What if I grab some really high temp sealant and apply some to both sides of the gasket when reinstalling the manifold, and just leaving the broken bolts where they are, as it appears they're pretty happy with not moving. Of course I have new gaskets and new hardware. Heemeyer, sometimes reasonable men must do unreasonable things. People are going to sneer at my idea, because it's not a very good one, but in the words of Mr. I've been thinking about doing something I absolutely do not like to do, and that's to cut a pretty sharp corner here. The third port from the front of the engine. One is at 1 o'clock and the other is at 7 o'clock. The broken bolts are on the same port, one above the other, kinda. My only option to removing them is to drill the entire bolt out, and I'd rather not do that. Not even some heat from a oxy-acy torch could get them to cooperate. I've been able to extract all but TWO bolts that have broken off flush with the engine. I was able to replace the gasket on that side easily. The driver's side manifold came off easy with ZERO bolts breaking off. Wrenching on my 2003 Durango 4.7L, and I'm replacing exhaust manifold gaskets.
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