Well lets start this by disclosing the fact that I am an idiot. I broke off my oil pressure sensor, which threads directly into the block. Then I broke off the easy out I was using to try to get it out. Not sure where one possibly goes from here but one friend suggested I try to weld a nut onto the easy out and try to get it that way. I figure it will be near impossible to drill it out now with that easy out stuck in there. Any ideas.

 

easy-outs and taps are very hard to drill.

Welding to it might be the only way.

Occasionally, it is possible to use a diamond burr on a Foredom tool to cut a screwdriver slot into the broken stub.

 

I agree, save your drill bits. I would also be nervous about getting metal shavings into the oil passage. If you can grab any part of the easy out, you might be able to carefully clamp some vice-grips on it. Clamp them on as tight as you can. Welding a nut on it is an option, but be careful not to weld it to the block and make the problem worse. Putting some welding putty around the outside of the easy out might help prevent an accidental weld on the block.

 

Can you share a picture? That'd help the gang strategize as this is a tough situation, one that we dread.

If there is enough exposed, yes, vise-grips are your friend. Get the deepest hardest bite you can, and try to work out the tool. You might also try blasting in some cold-spray to help get it loose.

If the vise-grips won't work, then I agree about cutting a slot in the face to get a flat-blade screwdriver into it. A Dremel works nicely for this. Again, cold-spray might help gain some clearance.

For future fastener battles, I really like the PB Penetrator product (or similar). Key is to be patient -- wait hours or days with periodic sprays for it to work its magic.

 

In addition to the penetrating oil of whatever sort you prefer, I've found that, especially with the standard screwdriver, if you apply the twisting to the screwdriver, while tapping on it with a ballpeen hammer, it can help.
Even when using the vice-grips, if you tap on the item that's stuck, it can help. Ballpeen hammers can be a huge help breaking stuck things loose. A good hard tap, or even a whack , will have beneficial effect quite often.

Not always, but quite often.
Good luck!
Pat☺

 

Another option: In addition to slotting the EZ-out so you can use a flat-bladed screwdriver, you may want to consider a hand impact tool. These were essential in my past for removing Philips-head motorcycle case screws without stripping them. Basically, you push into the fastener, apply torque with your hand in the desired direction, and whack it with a hammer. Can work wonders.

Just a thought

 

That's an even better way that "tapping" on the screwdriver with a hammer.

What's odd, is that I have one of those sets, and completely forgot about it until just now.

Thanks Blueman!
Pat☺

 

Lots of examples of this on YouTube. Your local machinist is probably going to burn it out with a torch.

You could always braze it closed and use the other port under the motor mount.

 

My local shop welded a nut onto it and removed it. Afterwards they noticed a small crack in the block. FML.