Arggg...

He has the screw extrator stuck in it the hole.

The material used for the easy screw out extrator (I call it easy to screw up extrator) is the SAME material as most HSS drill bits. You CANNOT cut tool steel with tool steel, thats why people invent surface grinders.

Yes you can use drills made out of a harder material to drill out the easy out. The only drills I can think of is either a standard right hand spiral solid carbide stub drill OR a concrete drill (masonary drill) with a custom grind on it. I doubt you have a bench grinder with a carbide wheel mounted on it if you do you can do it.

The idea of Helicoil is for you to drill and tap the hole a hair bigger and use the same stud.

Use a concrete drill, use HEAVY oil with SLOW speed high pressure on an electric drill, DON'T put the hammer on. Watch out for the drill to wonder off and steering off center since they are known for that. You would have to sharpen the carbide on that drill every 2-3 minutes and DONT just use those black hardware store grinding wheels on a bench grinder to sharpen carbide drills because that WILL make the wheel blow up in your face and it will HURT.....

Trust me on this, I know exactly what I am talking about since I'm a machinist.

If that STILL doesn't work you'll have to take the head off and have a machine shop EDM that mess out for you which would probably cost more than the head itself.

I went through the same thing with an exhaust stud in a KA24E head a few months ago. I tried the extractors and of course they didn't want to work. I've had one break on me before so I knew when to say when. I drilled the whole stud out and just used a helicoil kit. It ended up working fine although it wasn't very pretty since it was my first attempt at using one. But getting back to your problem I think if it was me at this point I would just cut my losses and take it into a machine shop. Those guys are pros and can work magic when it comes to that kind of thing. You might just make things worse if you keep working on it...

I am f*cked now lol. I got one size bigger extraction bit... tried that and the tip broke off in the broken stud! I tried drilling it out but the material with the bit is alot stronger so it isn't even getting dented.

Any other ideas now? Maybe jbweld the broken stud in and just don't tighten to spec?

The car is in my garage right now with everything off it so it won't really be possible to get it to a shop. Guess I am going to have to resort to copper gasket and hope it holds up.

I got the screw extractor peice outta the hole and redrilled for the tap... tried again and it was actually working I was so happy lol but then the damn hand peice that holds the extractor bit started to corkscrew so its all fucked up... now the hole is really fucking big so I might have to resort to the helicoil which I might add cost me $60 at napa :O

It ended up working fine although it wasn't very pretty since it was my first attempt at using one.

Do you have any suggestions if I need to resort to the helicoil as far as making sure it is done right?

60 bucks seems a little much... i got mine for $20, including the tools to do it.

Alright well I go to put the stud in but of course it's going to be tough so I put a nut on the end to tighten it down with. But when I got to get the nut off it backs out the whole stud. Is there some trick to putting the new stud in or am I supposed to be screwing the new stud in with some type of compound that holds it in there better?

Well, I have TWO bolt that broke INTO the block. DId you guys find any other ways that might be easier?