Stuck upper caliper bolt 88 mighty max

Caliper started leaking about a year and a half ago so I got new ones to replace. I’m no expert mechanic but I’ve changed a caliper before and it wasn’t that bad. However the top bolt got its head sheared off and it’s been a nightmare trying to figure this out. I tried using a pin punch and ez out but couldn’t get behind it well enough, so my father in law cut off the old caliper then made a mess of the bolt trying to weld a nut in there. I think he ground a slit in there too for some reason. We tried an ez out on the side we could access but the ez out ended up snapping off in there. I sanded the sides of the stud flat to get a vise grip on it but that didn’t work either. Now I’m back to trying a welder again because I don’t think fil was approaching it right, but after welding it once I am having some kind of spooling issue with the welder so need to fix that. I’ve also been spraying it with liquid wrench every weekend this whole time. I’m at my wits end and am running out of ideas. The other caliper came out with no issue. I just want my truck back.

I had to drill out some exhaust manifold studs on my dakota. The unbroken bolts and stud nuts came off when I hit them with a oxy/acetylene torch made them cherry red then removed the fire. After about a minute to let them cool enough the socket would not deform the nut they came right out. Do not use propane as it will not heat it up fast enough on just the bolt to cause the hot/cold difference that will break the seal from expansion and contraction of the bolt.
Drilling out the broken studs (about 1/8") I used left handed drill bits and a rotary file. Thank you Harbor Freight for both tools.You need to run the drill backwards. Start small work up. You might need to go larger with the overall hole and tap it for a new bolt if you can't drill the broken easy out. That nut thing should work if you can get it welded.

GREAT ADVICE 85Ram50..!

There are times that a 1/8" or 5/32" 6011 welding rod with 200 amps can act like a cutting torch too, hee hee... Harbor Freight might even be selling carbon arc cutting torches (?) when using them move in the direction of Rod followed by the Air, hee hee...

NOTE: For very precise work have a helper to connect & disconnect the welding cable (say ON/OFF) that way the 200amp powered 6011 rod won't miss the spot to be melted out or off... hee hee

Have Fun,
Old Navy Anchor Builder