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I have drill out the stud as large as I am comfortable with doing using a hand drill - there is hardly any bolt left. It is just a gaping hole (do not remember the exact drill size) but there is just enough material left for a big easy out to bite on to. I have learned that you can drill out an easy out if it breaks - use several cobalt drill bits and a lot of patience! I gave up yesterday but will work some more tonight on this.
I think I will heat the whole thing with the propane torch and see if it loosens at all. Let's all be realistic with the torch - it is not a precise instrument and you end up heating both the both and the surrounding metal, there is no way to only heat one or the other. Regardless, I will apply heat for a couple of minutes and hopefully it breaks loose this time.
I guess if the heat and easy out do not work, I can just cut new threads in the drilled out bolt - the thread size is M8 course thread (.125) correct?
What a pain in the neck this has been!
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Threaded Mode
