Some of the hardest things I ever had to fix were broke off bolts in aluminum.That white stuff gets set in there like concrete.If you can get the bolt hot and let it cool off good,it might come loose.You will have to work it both ways,if it moves you can get it.Just move it each way squirt with penetrating oil,heat.If you have room,you could weld a piece of flat metal on it with the wire feed instead of a nut to make a handle.That way you can see better if its turning or twisting off.Dont twist it off,just move it a tiny bit both ways until it loosens up.It has to move,and you might have to heat it several times to get it to move.Drilling a hole completely through it helps to get heat all the way through the bolt which is important.If you can get that whole piece hot all the way in,and not melt the aluminum,it ought to come out.You have to be careful not to melt the aluminum,but it has to be hot and cool off so it stretches that white stuff and releases the threads.You could try hitting it with an air hammer,a hammer and chisel,punch.Maybe even cut a slot in the top of it and try a screwdriver.Try to tighten it first a little.Its hard to get them out but if it moves you can get it.You just have to let it cool off before you try to get it out so you dont tear a chunk out of the head.Try and concentrate your heat only on the bolt because you cant tell when aluminum is too hot,it just discolors or melts real quick with no warning.You have to be patient.You already know its not going to come out quick.All the time you spend on this will teach you how better to do it the next time.Exhaust bolts get hot and cold their whole life and it makes them brittle.Its hard to get a brittle bolt out of aluminum if its stuck,but it can be done,usually not very fast.Hitting it with an ice cube sounds like a good idea,especially if you have a hole drilled all the way through it.
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Today's Featured Article - History of the Nuffield Tractor - by Anthony West. The Nuffield tractor story started in early 1945. The British government still reeling from the effects of the war on the economy, approached the Nuffield organization to see if they would design and build an "ALL NEW" British built wheeled tractor, suitable for both British and world farming.
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