Originally Posted by Timothy'* Buick
4.3? Its a cast iron block for sure. I'm sure the heads are too.
I imagine the block is, but it turns out the EGR valve is mounted to the intake manifold, which is aluminum. So, we're both right!
Can you weld a nut on the easy out? I've had lots of luck welding a nut onto broke caliper bleeder screws, sunk into the calipers. The heat from the weld actually can break loose the rust barrier. For this to be sucessful, the metal must be clean clean before you weld, or you don't get good enough penetration.
Now that'* something I didn't consider. I thought he should have tried at least heating the area with a propane torch; aluminum expands faster than steel, so it should have loosened things up a little.
I'm a bit scared of getting near the aluminum with oxy-acetylene, though. I don't know anybody with an arc welder I could borrow, either, and I don't have any experience with that, yet.
First I'll see if I can tease the chunk of EZ-out out of the hole it'* in. If I can do that we can at least try to drill and re-tap the hole, or somesuch.
Any other approaches to getting the sheared off bolt out, or other guidance and suggestions? I'm all ears!