Exhaust manifold stud removal

[123abc]

After the whole drill, break drill bit, try easy out, etc. I've found that a torx bit can work really well if you get the right size and use a hammer to get some bite. I was able to do two studs that were an eighth inch inside the head using that method.

[Tachyon]

I have an incredibly sharp carbide needle punch that I use to make a dimple in the center of the stud. Once I've hammered a nice indentation where I want it, I start drilling a pilot hole with a very small drill bit. It's important to use a very low speed when starting this hole.

Next, depending on how things are going, I either incrementally start increasing the bit size, or if it's a well centered pilot hole, I immediately switch to the bit size for my Easy-out. With the hole drilled, I tap the Easy-out gently into the hole, then with the drill set to a low speed, reverse stud out. It's never failed for me yet