Hmmm...you might be able to get a nut to work, but I've always used a bolt... I made a visual to explain
.
Pretend for a second that the nut you see here is your engine block, and the bolt threaded into it is the broken off one.
All you have to do is find another bolt slightly smaller in diameter...you want to use a smaller one so you have some room on the side to put the weld. Then, just weld the tip of the new bolt to the stub.
It will look something like this when it's done...
Then, just put a ratchet on the new bolt and turn it out
. Pretty much any MIG or wire feel welder should work, though yea...I probably wouldn't recommend using this as a way to learn how to do it
. Would be a good idea to cover as much of that area as you can to keep it from getting damaged by spatter too. It's too bad you're not in my neck of the woods, I could probably have it out in a few minutes...
And I definitely feel your pain on the screw extractor... The last time I used an easy out was summer of 1995. I was rebuilding the 394 for my Olds, and I snapped off an oil pump bolt. I didn't want to pay a machine shop to remove it, so I bought an extractor. Drilled a hole in it, and yea...*snap*. I still didn't want to pay a machine shop to remove it, but I did. When I called and asked them how much it would be they gave me a price (I forget what it was, but it wasn't too bad). Then I asked "What if there's *cough* and easy-out broken off in it *cough*"
"Oh...yea, maybe you should have called us first, that's going to be...more."
They were able to get the whole thing out, but it wasn't cheap.
I've heard stories of people who have used them successfully, but I'm not one of them. I'll never use one again as far as I'm concerned. YMMV, of course
. Anyway, hope it comes out ok. Welding gets things very hot, very quickly, but in a very localized way...it's great for getting them to give up and come out.
And my brake calipers were pretty bad too. Be careful if you use compressed air to pop the pistons out...wear hearing protection, and have a pile of old rags over them as when they do let go, they come out with a lot of force (and sound
). I just close the bleeder, and then put a blow gun in the hole where the banjo fitting goes...hold on tight, and squirt shots of air into it. Once one comes out, you have to put it back in just slightly, and then brace it with an old brake pad or screwdriver or something so it holds pressure to force the other one out. You can also use a grease gun to pump them out...it's more work since you have to clean up the grease after, but lacks the danger and excitement of using an air compressor.