It broke because its a 30 year old steal bolt in an alloy housing which has been heated and cooled a thousand times....Its just what happens,im fixing broken studs on manifolds all the time. :)Some one probably already had a go at it....Ill throw a spanner in the works...Even a proffesional can have trouble,ive broken plenty,but ive been lucky and always had a way out some way or another,its hard to give advice when we are not standing there doing the Job, I just want to grab it and fix it lols...ok so there is not enough of the face to grab hold of...would it hurt to linish it down flush,centre it and start drilling? If you get centre you will be fine with at least this part,then reassess it when youve doen that?. Just my thoughts,But trully if your not confident,try and get a pro to do it ke you said....Its just nice to be able to do it all yourself,regardless of the outcome...live and learn right? Although I do have a spare engine if you stuff this one up...Just teasin! smile