While getting my Kohler 482S ready to install the "new" exhaust manifold, several things happened. Not surprisingly, two of the four bolts holding the manifold to the block snapped off. I've been soaking the stubs in PB Blaster for several days now, alternating applying heat and tapping the stubs. They're both still firmly rusted in place. I bought a drill extractor set (Easy Out) and will tackle drilling them out today or tomorrow. That's not the real problem, however.
While removing one of the other rusted-in bolts (which did come out), the tab or "ear" that it screws into on the cast iron manifold broke off. I have been staring at it for several days now, trying to figure out what to do. I DON'T want to replace the block! I'm considering drilling a new bolt hole through the tab on the manifold and then drilling and tapping the corresponding spot on the block. It looks like there is room to do that on both the manifold and the block. The broken part is on the left cylinder.
Any thoughts or advice from the forum on what I should do to fix this?
Picture is attached. And yes, the block is really dirty. That was to be my next project, before this problem happened...