Got'r fixed
Well, after Plan "A" failed, I tried Plan "B" and it failed too (I bent a 20-year-old screwdriver that had never bent before... ever). I took the manifold off and welded a nut onto it, then promptly sheared the stud in half almost flush with the flange. Grrr....
So, I drilled it out after all. After all this frustration, it was so quick and satisfying to spend less than 20 minutes drilling, then 30 seconds with a reverse-twist 1/4" drill bit to wind the remainder of the old stud right out. I cleaned up the manifold bolts and had the whole job done in an hour after that.
The only drawback after it is all done is that the guy who welded it didn't weld the two halves back together totally straight to one another, so the flange behind the cat contacts a bolt head on the frame that it used to clear by 1/8" before. Oh well....
Scott
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