I have drilling for some time...
my last drill bit size will be 1/2 Do i need go any bigger?
I know the bolt size is .522
So i'm worried..
Once you drill deep enough [to the diameter where the threads start], the lug will be thin enough that it will be easily fractured and will come off.
The final note - "The pursuit for a Passat/CC 4Motion performance exhaust"
'Ein Trottel nicht an der Tat zu hören"
The minor diameter of the thread is .4725" , so drilling @ .500 will leave you about .020" wall on either side of the bolt if your dead center. At this point you should be able to use an easy out or screw driver to unthread the remaining portion. Make sure to use a little heat and lubrication (WD-40 or Kroil, ect) to prevent any galling.
Seems like drilling was a poor choice of extraction methods... I have had to remove countless stripped or locked lug bolts/nuts, and drilling was never the chosen method. I have always used a tapered lug socket with 100% success.
That method can't be used now, but keep it in mind before pulling out the drill if it ever happens again.
Drive lowpark lower