I've done this before on a cracked engine block using hand tools. It took a long time to do but it worked in the end.
ETA: On the other hand, I knew a guy that twisted off a water pump bolt on a six cylinder Ford and when he went to drill it out he kept drilling until he drilled into his #1 cylinder. He was lucky because the piston was down in the cylinder when he drilled. He took the head off, got all the metal chips out, dressed up the hole edges and packed it with JB Weld and when hardened he put it all back together. That car was still running fine two years later when he sold it. I'm jus' sayin' ...

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