Or wheel out "The Disintegrator"....muuuaaahawwaah

http://www.cammann.com/

http://www.ebay.com.au/itm/ARTU-7-PIECE-METRIC-DRILL-SET-4-12mm-ALLROUNDER-DRILL-THRU-HARDENED-STEEL-/160736438579?hash=item256ca36933:g:ZmsAAOxyhXRTMj~Y

Jenk,
These drills Will Drill out an Easy Out.
I have used them on high speed steel many times. Easy outs are softer than high speed steel.
Believe me they will work..
You will need to set up a drill guide so you are sure to drill down the center of the broken bolt and easy out combination.
A simple drill guide could be made with a piece of mild steel with a hole in it the size of the drill you are going to use.
Bolt it to the block using the other steady mount hole and another suitable point.
Position the hole in your drill guide directly over the broken bolt hole.. Guide should be about 20mm thick
Dont try to do it without a drill guide, it will end in tears!!!
If your not sure PM me and ill send you my mobile number and talk you through it.

Hi Dave,

The easy out is no longer square at the top where it snapped as I'm sure you have already assumed... do you think the drill guide will still keep the drill straight given its now jagged? I really appreciate the offer mate I'll let you know how I go just need to round up some 20mm mild steel and give it a crack. Thanks again.

Also if I'm successful with drilling out the easy out, how do you suggest I get out the broken bolt (the original problem) should I just drill it out as well??

cheers

Dave

Take Mick's suggestion... I could tell you where to go in Canberra (seriously:) but you'll have to do your own search in Sydney.

It was cheap, quick and left the block absolutely untouched. I think they may also be known as a plasma eroder ???.. I'm sure someone will know. And I'm sure one of the quality engineering shops would have one.

Cheers, Ian

Those drills look interesting.

true champion that he is even offered to make the jig and send it to me from Melbourne... What an absolute legend of a bloke!! Off course I will be buying him a case of beer or two, it just restores your faith in humanity to see that there are still such good people willing to help out there!! your a legend Dave!!

cheers

Thanks SCA1PER Ive tried tapping it out with a centre punch... no good, not sure I want to smash it out either appreciate the advice.

Doc the engine is already out subframe and all so this will make it easier but I really like Dave's (sitnlo62) idea of making a drill guide that will bolt to the side of the block via the other engine steady hole along with one of the crankcase bolt holes enabling you to keep the bit completely square whilst drilling out the easy out with one of those you beaut drill bits. Dave... true champion that he is even offered to make the jig and send it to me from Melbourne... What an absolute legend of a bloke!! Off course I will be buying him a case of beer or two, it just restores your faith in humanity to see that there are still such good people willing to help out there!! your a legend Dave!!

I will photograph the set up once I have it bolted in place to give you all a better idea/understanding of Dave's idea.

cheers

I used Dave's drill jig today on Jenk's S block in my bench drill. Drill bit it uses is an ARTU 6mm `all purpose drill', it appears to be solid carbide with an insert (stellite?) in it. Running at 2,250rpm, it made short work of the ezy-out.
I then removed the jig and drilled it out (slower!) with a 7.0mm HSS drill, and ran the 5/16 UNF plug tap into it by hand in the drill chuck. This peeled the bolt thread remains out.
Thread in the block is still perfect. Some swarf is showing in the pic.
Note I just sat the jig back on for the pic, it's not bolted down.
The welded bracket sits on the flywheel housing flange if using it in situ.

pics-