How to remove bolts that are broken flush.

Here's a water outlet with a broken bolt in it. The owner of the car tried to drill it and use an easy out with no success. This procedure works better if the bolt hasn't been mutilated with bits and such, but it is what it is.

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Find yourself a few nuts that fit over the broken bolt. I have a big old sack of nuts, so if I bust a nut the first time, I can try again. No pun intended.

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Weld in there:

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Then simply unscrew: (TIP- You may find penetrating oil helps loosen things up a bit during this step)

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Chase the hole with a tap, and smooth off the area with some 1500 grit paper and a sanding block.

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Viola my friends!