Exhaust manifold stud removal

[iceminion]

Since the dawn of my dsm days I have been challenged with many platform-specific issues; one of which I have not found a reliable solution to: exhaust manifold stud removal.

Now if you are lucky, you can remove them in one piece, this can usually be accomplished by firmly attaching a vice-grip to the stud (manifold removed) and work it back and forth until it is free enough to be twisted out.

Once the stud is removed, buy the stainless stud kit from one of the many local shops or online sites. Flawless victory!

Now what if you have a stud that is broken off flush with the aluminum, or worse: broken off INSIDE the head a half-centimeter or so?

In the past I have taken the head to a machine shop where I drop it off, and the next day: issue resolved. Once I even brought a complete longblock in (to save the headgasket).

I assume the best home based repair would be to use an electric hand drill, but in practice, it is extremely difficult to keep the bit centered on the stud and not walk onto the soft aluminum. Maybe a solution would be to get a dremel tool and a carbide bit, build a jig of some-sort to insure that the hole cut is true.

I'm just putting this out there. What have other members done to solve said issue.

Thank you.