Use Old HE Flange for Drill Jig?

[Porsche84]

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.

[john walker's workshop]

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.

[Tidybuoy]

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.

Broken Exhaust Stud - Fixed :) Photos of My Repair


Vern

[arbita1]

Originally Posted by john walker's workshop

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.

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

[arbita1]

Thanks all!