i am at the end of my threads

[firebird77clone]

I like the torch suggestion. very risky, but after you break off an easy out, not many choices left. That easy out is HARD.. so even with a carbide four-flute ball end mill, you have a chore ahead of ya. Before you try to mill it out, you could heat the end of the easy out cherry red, that'll take some of the hard out of it.

Tip for the future... if the bolt shears off because it is seized up with rust, an easy out will NEVER work. If the bolt sheared off from over-torquing, then you have a good case for an easy out.

Another tip ( just remembered ) is to SMACK the bolt with a hammer ( 32 oz ball peen ) before you try to remove it. Sometimes that will bust up the rust some. Penetrating oil is sometimes helpful on exhaust bolts, but not usually, as it just cannot get to the threads. ( bolt is too long )

Last tip: for exhast studs, ( or any rusty nut ) heat it till it is dull red ( or almost dull red ) and apply some light oil ( turbine oil works well, available in appliance parts stores and has a wonderful extendable tube spout ). the heat will draw the oil into the threads. Repeat several times, and the nut will usually come off with a minimum of resistance.

Your best choice for a twisted off bolt is always to drill it out and run a tap down to clean the threads. Drilling free-hand, my chances of getting a perfect center is low.. and I do try hard! A center punch helps, as does starting with a 1/8" drill and stepping up by 1/16"s.

If ya flubber up the threads by drilling out, you might be able to drill out and tap to the next larger bolt size. You can also helicoil, which also requires overdrilling. There are several thread inserts available, which require overdrilling as well. Usually, the helicoil gets the job done with a minimum of oversize.

Sometimes it is better to just 'cut your losses' and take off the head, and bring it to a machine shop.