Get a pick or something pointed, insert it between the threads and the remaining metal and pry it toward the center. Time consuming but necessary. You should be able to run a tap in the hole without cutting much metal so you do not cross thread or remove metal from the threads in the aluminum.

don't use a cleanup tap until you get the remaining threads out. a small punch ground to a sharp point and a small hammer to get it started under the edge. pry it outward and grab with small needlenose pliers. some pull out like a helicoil. some break and you have to go in again for the rest. patience.

Attached is the link of a post (with pics) that I posted some time ago regarding drilling out an exhaust stud on my 944. It's a different situation and engine but the process is similar.

http://forums.pelicanparts.com/porsche-924-944-968-technical-forum/550019-broken-exhaust-stud-fixed-photos-my-repair.html


Vern

Ok. That's what I thought, but I was afraid to start doing that without checking first.

Thanks all! http://forums.pelicanparts.com/uploa...1319909495.jpg