I had the exact same thing happen last fall on my GM product. There was a pretty good amount of bolt left to work with, as just the head twisted off. I alternated between the propane torch and soaking it with penetrating oil for awhile. At least one overnight soaking with penetrating oil too. Because there was plenty of room to work with tools around the bolt, I took an angle grinder and ground "flats" on two opposite sides of the bolt. I had to use a flat file to touch them up a bit. This gave me the possiblity of a good grip with locking pliers.

I have a set of long-nose locking pliers that are not particularly heavy duty. I used those (because they have flat gripping jaws) to grip the bolt. Then I took a heavy-duty set of locking pliers and gripped that from the top (same axis as the bolt). Then I think I took some really big adjustable pliers (the kind that have multiple tracks to set different working jaw openings) to grip the heavy-duty locking pliers and twist.

It finally broke loose and came out.

During the process, I repeated the following mantra several thousand times:

I will not insert a steel bolt into aluminum without using anti-seize.
I will not insert a steel bolt into aluminum without using anti-seize.
I will not insert a steel bolt into aluminum without using anti-seize.
I will not insert a steel bolt into aluminum without using anti-seize.
I will not insert a steel bolt into aluminum without using anti-seize.



Ken300D