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I've used EZ-outs successfully times, and I have also broken one or two (of the smaller sizes). Some things that I have found along the way to help are:
1. Use plenty of P-Blaster, soaking the area a couple of times, starting several hours before you plan to use the ez-out.
2. If you have access to a left handed drill bit set, use one to drill the hole for the ez-out, I've had broken bolts come out with just a left handed drill bit already
3. Make sure you drill the hole for the ex-out as straight and centered as possible.
4. Use some heat if posible (nothing around the area will get damaged), a small, cheap propane or mapp gas torch can really help sometimes.
5. The smaller the ez-out the more likely you will break it off. If possible, always use the correct size tap wrench to turn the ez-out (after tapping it in with a hammer), other alternatives are a 16 or 8 point socket of the correct size, vise grips will work, but are one of the least desirable options (at least for me)
6. Don't put too much pressure on a small ez-out, it is next to impossible to drill out a broken off ez-out. If you can't get it with the ez-out, be prepared to drill out and heli-coil the hole or take it to a machine shop to get redrilled and tapped.
Most of the time I've had success with ez-outs, just prepare the area carefully with heat and P-Blaster, and take your time removing the broken bolt/stud.
-Keith
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