I just wanted to update everyone on a neat little trick I learned.
When I tried to pull the manifold, I snapped both bolts off flush with the surface. (Why am I not surprised?) After cursing a little, and moving throught the 12 step program, I finlly accepted my current situation and broke out the drill.
Drilling bolts always makes me nervous, because try as I might, I am never able to drill down through the dead center (even if I use a center punch). Which is what happened to me on this occasion. So, after the initial drilling I started gradually drilling bigger and bigger (1/64" at a time) until I barely could make out the threads on one side of the hole.
This is where the trick comes in.
Break out your dremel tool (real cheap knock-off's at harbor freight) and chuck up a tungsten carbide cutting bit.
http://www.toolsdirect.com/dremel-9...source=gba_121178&CAWELAID=161922025Mine was similiar to this, but slightly cone shaped and about $9 at Lowes. It takes a little while, but slowly hollow out the inside of the hole you drilled until you can just start to see the threads all the way around. (WARNING!!! If you have a fear of the dentist office, this sound might make you a little uneasy haha) At this point I soaked it in PB Blaster (since there was lots of surface area for it to soak in through.
I was able to literally able to un-coil the remaining bolt threads out of one hole, the other I was forced to cut it out using a tap (it cut through about half of it, and then pushed the other half out the opposite end.
I then finished it off by running the tap through both, until it ran smoothly.
VIOLA!!! perfect original threads, no heli-coils, and no tapping to a bigger size! Now if I could only get that darn heat-riser flap un-stuck....
