U can count my little garage in on that ban as well!!!!!

Easy out is actually forbidden in a lot of machine/engineer shops :D

Lady luck smiled upon me, found a gunsmith that does spark eroding. Removed the easy out then drilled the hole to size and then he retapped the M8 thread.
Good as new.
Thanks for all the advice !!!!!
I think the name easy out should be replaced by something like "bad to worse" !!!!

using a piece of thick steel plate is the best idea but theres is hardly any head to damage the head which ever method you use.
Yet the plate is a perfect one piece leverage and welding clamp piece.

I've never had success using an easy out.

+1 on NOT using an easy out

they work by trying to get stuck into the offending bolt but if you crack the sides of the bolt then you will stretch the alloy casting - did that to my auto g'box and broke the side out of it,

ddiesel - I like your suggestion

Ezy outs are useless eh. Get some 3mm plate - say 25mm wide and 300mm long. At one end drill a 10mm hole in it 20mm from the end. Clean the area around the stud really well with thinners or such. Clamp the steel to the manifold face so the 10mm hole is concentric with the stud. Zap it hard with the mig. Use the steel as a lever to GENTLY rotate the stud out. If its sticky (and it will be) rock the lever back and forth a little before trying to undo it. If that doesnt work get it spark eroded out.

I would advise using an easyout or getting a head shop to do the work, heating heads is a sure way to anneal the material leaving the head prone to failure/warping.

I welded a nut to the stud to get it out of the block. For that you need max heat, totally clean and no slag in the bottom. If you use an M6 nut it should blind the head so there's no damage. You might get a brittle weld though since there's an easy out in there. SO long as you don't bump the nut and burn a hole/ crevice in the head face.

Like the others have said the sudden heating can help break it loose. If nothing else it'll be easier to start the drill.

Let us know what works!

a simple spot weld takes like 1-3 seconds max with an Arc welder nothing serious, difficult or enough heat to weaken the alloy. Let it cool which is bugger all radiation from the stud.