Hmmm... welding a nut on the stud sounds like a great idea, and way easier to do than drilling the stud out.
I didn't think of a Propane torch. I've got one of those. I would definitely want to have the manifold off the car for that. I just don't trust open flame in any engine compartment unless all the fuel lines have been removed. A family friend burned his garage down when I was a kid because he tried to solder a wire connection in his engine compartment with a Propane torch inside the garage, and he burned his hands pretty badly trying to push the car out into the driveway.
I didn't get a chance to attack the stud tonight, but I've got all day tomorrow. We'll see what comes of the day.
Thank you all for the great ideas.
Scott
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