holy christ...i was slowly taking off my 1rst drivers side manifold bolt (closest to front of car) and it was going fine ..i wasent even using much force and pop! the header bolt breaks and falls on the floor... now half is stuck in the head...what am i gonna do??

 

at least it wasn't the back one like mine was. I was able to just put the on and the 1" bolts didn't bottom out. I got pretty lucky. Since it's on the front and you can get to it, just use a screw extractor.

 

You're gonna get an extractor.

 

Remove the rest of the bolts and manifold. If you can get a "genuine" vice grip on it, un screw it.

If not, get an "easy out." JMHO

 

If it broke off flush with the head surface you can sometime cut a slot in the bolt with a dremel tool and use a big screwdriver to unthead it.
If the threads are screwed, and they probably are, your going to have to install a Heli-Coil. Most auto parts have kits.
Any time you install bolts into aluminum use anti-seize compound.

 

check out my cardomain page 6..got pics of this shiz-nit

 

pg 6 has got pics of the bolt stuck flush in the head...whats the best trick/tool...what should i try first?

 

The neatest trick I've ever seen and according to the mechanic it works every time. Is to warm up the area and drip candle wax on the bolt. I know it sounds hokey and how the H@#$ do you drip wax sideways. If you can do it, then try rotating the bolt with a pointed punch and hammer at the edge off center.

If that won't do it for you, warm the area and soak it with penatrant like PB Blaster for about an hour or more and use a left hand drill bit. I caution you about easy outs. They break real easy and then you are up S@#t's creek trying to get that out.

Start small at first and be sure the bit is centered in the bolt. Then continue up in size until you have the biggest possible hole in the center of the bolt without damaging the threads. Now you can use the maximum sized extractor.