Fixing exhaust leak mistake

Had a customer come in that has an exhaust leak. The manifold is cracked and has a broken bolt. Upon removing the manifold found someone tried to extract the bolt before. Work was poorly done damaging the cylinder head and enlarging the bolt hole. Used a guide to recenter the bolt and drilled an oversized hole to installed an insert to correct the previous repair.

Broken bolts are tricky. Some come out easy while some are really difficult. The right tools and equipment can make the difference in a perfect job or one like I found here.