So i have my nice pretty engine sitting in front of me. Freshley rebuilt and painted and now freshley broken =(. Anyways somewhere in transit one of my exhaust manifold studs was broken or just really stressed because when i went to put on my manifold the stud snapped right off. Thinking it would be no big deal, just drill it a little and use an easy out to pull it out, well that didn't work. All it did was tear the hole i drilled in it all up. so now i'm stuck, what to do do i just drill the whole bolt out threads and all in the housing and try to run a heli-coil in it or should i stop where i'm at and try threading it and use some extra washers on a smaller bolt to hold the manifold on or just say the hell with it and attach everything on with 3 bolts and hope it doesn't leak like crazy.

 

It'll leak with 3. I'd find the smallest hardest bit you can find and start with that, and then just move up in size from there.