Tips for removing a sheared exhaust stud?

Hey,my mate sheared one of the studs for my manifold so its blowing like hell.Took the manifold off but its like a good 2mm inside.Was gonna drill it and tap it but dont have a tap n die set,other option was to tac weld something on to the stud and unscrew it.As far as im aware it isnt seized in as i had it out not that long ago.Last thing i could think of if worst comes to worst is to weld the stud back inplace.Any other ideas?
Cheers
Jamie

Drill it out, but make sure the drill is sharp! If you use a blunt drill bit, it will just heat up, rather than cut through, and "work harden" the area you want out, making the job 10x as hard.

Also bear in mind you need the right size drill bit. For example on an M8 nut, its not 8mm because that's the measurement of the outer part, not the inner part, of the thread! There's tables on the internet for standardised thread sizes which will give you the inner diameter you require. Hopefully by drilling close to the required inner diameter, you can pick out the remaining bits of bolt and if the the thing was drilled carefully with no thread damage, wouldn't need re-tapping but could be cleaned up by, eg WD40 on a rag pulled through a few times then a bolt of the equivalent size run through it.

Cheers paul,yeah i had that suggested to me before,im just scared ill screw up the threads.I think i will try that though as it seems the simplest way of removing this stud.I just got a whole new set of drill bits aswell so i can christen them.Ill let you know how i get on if the weather lets me work on it tomorrow!

As you have the manifold off, take it to a good exhaust shop. They almost all have a welding fixture that welds a new stud to the old one in cases like this. If you decide to go with drilling, remember the stud itself is case hardend so not only sharp, but a very good quality bit.

find a snap-on dealer and get a stud extractor set. they come with left handed drill bits (no this is not a wind up) chances are that youll never use the stud extractors coz when you drill the stud because its a left handed drill they usually grab hold and wind the stud out and if it doesnt youve got the extractors there ready.. they cost ?47 for the set and there great. im a heavy plant fitter for a demolition firm and use them all the time for bolts that have been snapped off.

Is that the snap on easy outs ur on about?My mates got a set but theyre at his work and hes jus been suspended pending an investigation so cant get to any of his tools.

Cheers grimey,yeah theyre good quality bits so theyll do the job.Think iam just gonna try to drill it out,seems the best way,then i can just re-tap the hole to clean it up if need be

I know easy-outs sound like a simple answer to the snapped off exhaust bolt, but be very careful. If the easy-out breaks when trying to remove the bolt you now have a hardened chunk of easy-out to deal with, no fun! An easy-out works well for many bolts but I would avoid using one on the exhaust system. I've broken a Snap-On socket trying to remove a stuck exhaust nut before.

just one stud! dont worry use a new gasket and smear with silicone and it will seal,  two of mine are sheared and it doesnt blow

silicone,really?I thought it was one stud but it was actually 2,got the first one out no probs,drilled through it and re threaded ,the second one,the drill kept running about,gave my mate a shot and now ive got 2 holes side by side and im not sure which one is the stud.Anyway its a 4-2-1 manifold so will stuffing it with silicone still work?Was thinking on filling the holes ive got with some liquid metal stuff ,redrilling,threading and seeing if that will work.Failing that im not really sure......apart from packing more and more stuff in the gap haha.Any ideas?Apart from taking the block out as i dont really want to do that,im happy to run it blowing a little if i have to and get it fixed later on.

Forgot to mention another idea was just to drill new holes(s) through the flange on the manifold into the block and thread them,wasnt sure if the head was the same thickness all the way round,its a golf rallye block,sure its the same as the gti apart from the water jacket going round the whole block.