Frozen head Bolts

[THEFERMANATOR]

If they're stuck in really bad, I like to cut the bolt head off and try and pull the head off that way. Then you can heat and cool the remaining bolt a few times to expand and contract the materials some a few times. Then use a pair of parrot nose pliers on the bolt sticking out and heat the block up and then work it back and forth a few times. Remember the aluminum block will expand faster than the steel bolt, and the aluminum will normally expand more than the steel to. By heating the bolt and letting it cool off a few times will stretch the aluminum out some and in many cases allow you to be able to work the bolt out. I have had nothing but broken bolts with impacts though, so I use hand tools for any stuck in bolt now.

[lathehand]

I've used this method more times than I remember of as a tool and die maker.First start by drilling the head of the bolt dead center .The trick is to use a left hand drill bit .Yes they do make them.manny time befor the head has fallin off the bolt has turned between the heat and the left hand friction.If not you continue with the proper drill size for your thread left hand.That way if it hasn't unscrewed by itself you just have to clean up the thread with a tap.Hope this helps it's never failed me

[tsubaki]

I've tried each of the methods described above and haven't been able to make any distinction as to what's best.
Seems each bolt has it's own preference as to when it wants to come out.
As always I'm amazed and relieved when (if) it works and not surprised of a bad outcome.

[Kracker Jack]

This thread is giving me flashbacks of my old 200 yammy that was on my 24 seaox!! what a nightmare that motor was to work on. She was a corrosion magnet. sorry I cant help all methods that I would use has been mentioned

[phatdaddy]

i've had slightly better results with the maps (yellow bottle) gas over the standard propane. it's a hotter flame, but be careful, aluminum goes from ok to uh oh very fast.

[BRIELLY]

I hit it with the mapp gas today...Good news/bad news. The top bolt came out and I thought the next one was loosening but unfortuately it broke flush with the block. I guess its time to bust out the left handed drill bits and hope for the best. If it doesn't work itself out I'll robably have to try a helicoil.

[phatdaddy]

been there, done that....
except this is where i usually break off the e z out down in there.