The head popped off one of my DP bolts...what is the best way to take care of this?

 

you mean the dp bolt came off the flange ?

 

just pop the downpipe off, use some pliers to take that bolt out there should be at least 3/8ths sitting there to grab.. if that doesn't work cut a slot in the screw and use a straightblade to take it out (use a dremmel cutoff wheel or file if you have to)

 

I got the DP off...unfortunately that bastard is flush w/ the turbo

so should I drill in out, and retap the hole?
man this sucks

 

naw do the same thing with different tools.. cut a slot in the top of that screw and use a straight blade to take it out.. prolly have to get a small carbide bit to do it.. or if you can live with a slot cut in your turbo housing (which is ok, as long as it doesn't compromise the seal) you can use the wheel still..
they also make screw extractor bits so you can drill out the screw to x size, and use the extractor (reverse screw kinda) and it will unscrew that way

 

Next time, get a FLEX pipe welded on your downpipe! This will reduce the stress on those bolts when you shift hard! You can get a 14 inch one for $60 at JC Whitney.