RJ,
Not that you asked for advice on getting the stud out...but having a drill skate was the start of the problem. I've recently purchased a used set of dental drills that I use in my Dremel for starting pilot holes in this exact situation. I bought them as I had to drill and tap about 70 1/2 deep 4-40 holes into 6061-T6 aluminum for a project I was designing at work. About half way through I broke a tap in the hole...the part is worth several thousand dollars and the holes must be exactly placed. The dental drills drilled out the tap! I've since used them on broken studs to start holes after centre punching - works great.
Craig
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