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In my project I had 2 bolts snap off on me (not exhaust manifold). I was able to remove the part and take it to the local welding shop. Very carefully they built up a bit of weld on the tip of the snapped off bolt then welded a new stud/bolt to the exposed end of the bolt then with a wrench turn out the snapped off stud/bolt (i think you have to let it cool a bit).
I've been told, the welding heat breaks free the snapped off stud then its just a matter of attaching something to turn out the snapped stud.
When I removed my exhaust manifold bolts the engine was out of the car. I read numerous horror stories about breaking off the studs soooo... I started carefully and even soaking the bolts with penetrating oil and trying to remove the bolts by wrench, still no luck. I finally reached a point where I tried all I could being nice and I had to remove the manifold sooo bring in the bigger equipement, air impact wrench! I chose the correct socket size and held my breath. I thought for sure I was going to be another statistic BUT it worked like a charm. It must have been the hammering action.
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