Broken manifold bolt how to!

[shortbed70]

Figured since I just did four of them I would do a small write up on it.
This is my first LS motor and everyone said be careful removing the manifold bolts so I sprayed with pb blaster and let them sit then snap on snap two snap three snap four!!! So here's how I removed them!!!
Two bolts were broke flush with the outside of the manifold so those were easy. Get a 5/8 headed nut and wrench and place centered over the stud, then (I was usin a 220 welder) turn the heat up and burn the nut to the bolt around the stud so the entire nut is red hot all the way to the head, then let it sit until the color is gone. Let the heat work for you. Once you've waited about 2 minuits, use some penetrant or zipper ease (found at your local fabric store) and dab on top of the nut so it creeps in and your stud should come right out!
Now for the tough ones, flush or alittle in the hole... I used an 1/8" drill bit to make an indention in the center in the bolt so the welder has good metal to stick to. Now carefully tack weld right to the center of the bolt an build it up just outside the head surface. Now take a washer that will fit over the weld and bridge the gap around the washer to the weld. Weld won't stick to the aluminum but don't try too hard... The take another big nut and fill the center clear up to the outside of the head and once again wait a bit. Then slowly work it back and forth till it comes out.
The zipper ease works great for when the nut is hot but smokes like crazy. Take your time and this can be done pretty easily... Hope this helps someone save alittle money instead of going to the machine shop.. Here's a picture of what the nut looks like when hot! And my success!!!
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[shortbed70]

Success
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[82ZZZR]

Luckily mine all came out with vice grips ans penetrating fluid.

[mooseknuckles]

had to do the same thing with mine...6 broken bolts! worked like a charm tho...