Break an ezi out off in a casting and chances are you will need to use spark erosion to get the thing out. They are an excellent way of taking a situation from bad to worse. The very nature of their taper thread form means they expand the bolt or stud remains as you apply torque to them, which is self defeating. A crude but better way is drill the broken bolt / stud dead centre (MUCH easier said than done)and to a suitable size, and tap in a Torx bit, and use that to try and extract it.
Safest way is again drill dead centre, and drill oversize to use a Helicoil insert. Drilling something already bolted to an engine, in the car is fraught with problems, or impossible, if it's something like a cylinder head it MIGHT be worth making a drill guide to mount on unbroken studs or bolts. Especially if it's a common problem you see a lot of, like Skyline GTSt turbo manifold studs. Even then some holes are plain inaccessible even to a miniature right angle air drill.
Usually I remove whatever has the snapped bolt and drill it out on the Bridgeport milling machine, under controlled and accurate conditions. Gets expensive but better than knackering some expensive casting...Often quicker than buggering about for hours only to find it needs to come off anyway...
Attempts at home usually end up going disastrously wrong with an off centre, angled hole, with no thread left and still the casting needs removing, but now the job is infinitely worse to sort out.
I have a rounded off bolt in a front subframe to remove today.
Modus operandi : Clean the bolt head up to bright steel with a die grinder. Grab a suitably internal sized quality plain full depth nut. TIG the nut to the rounded bolt head, using a lot of tungsten extension and a big cup, the heat helping break the thread of the rounded bolt free. Unscrew with a single hex socket, BY HAND. Invoice accordingly, expecting the usual "HOW much". Admonish customer for rounding it off in the first place
