I was trying to remove a bolt that holds down the thermostat housing and the end broke off.

This is on my spare intake manifold that just returned from the machine shop, bored out to accommodate a 4.3 TB.

I drilled a pilot hole in the bolt a little ways, then used a screw extractor. Snap.

Tried using vice grips to grab what was left of the snapped bolt, also a propane torch. no dice.

I realized that maybe the end of the screw extractor might stop before the intake manifold surface, So I used a dremel tool to grind the bolt and extractor flush to the surface of the IM. You can still see the little bastard in there. I got a little overzealous with the dremel wheel and hogged out a dish-shaped bowl in the IM.

All the drillbits I have are not liking the srew extractor, they just sit and spin on top of it.

So first, how do I extract the snapped bolt and extractor combo?

Secondly, will JB weld work to fill the hole around the stuck screw once I get it out so I don't have any leaks? Or should I just supplement the paper gasket with permatex?

Thanks for any help

I DO have pics in the works.

Lesson: prep things going into your truck, before removing the things its going to replace from your truck. Thought I was being smart by buying a spare manifold, except I pulled the original before it was ready to drop in. heh