Easy-Out

[elanmac]

The best way is to use a lathe as mentioned previously, using a centre drill first then progressively larger drills until you get to the tapping size drill, the remaining thread will come out easily. If you lived locally I would have done it for you.

[edbear2]

Harvy was on the right track.....I've been in the aircraft/specialist welding buisness for 30 years, and have removed 100's of seized/snapped studs, bleed nipples etc. .....But find a good tig welder...build up the end carefully with a nickel repair rod (more strength) and drop over suitable sized UNPLATED nut weld this on, and before totally cool add a few drops of penetrating oil (the heat will draw it into the thread area....then carefully undo......my record for repeating this was 17 attempts!....but it was a hurricane hydraulic splitter casting that had been sat for 60 years that we wanted for a pattern!.....if you get stuck, pm me and if you are close enough, will do it for you or you can visit our workshop (malvern, worcs. area)