Any tricks to getting a seized corroded bolt out of aluminum???

The heads broke off, luckily they are studs with allen heads in them that I can access from the back. I have tried heat and pb blaster....no luck.

I am afraid I will break my allen, I am going to try welding nuts onto them to get a little more torque.

Are there any chemicals that will help break down the corrosion???

 

ATF and aceatone 50/50 works pretty good

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Also peen the head a little

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Heat the bolt or stud up to red hot and quench it as best possible. You might have to repeat this several times, but what it is doing is shrinking the threaded section so it will pull away from the corrosion.

 

PB Blaster seems pretty good at helping to dissolve rust. The PB, a little more heat and that welded-on nut oughta do it. Vibration helps too...a few raps with a hammer or an impact wrench.

 

If you heat the bolt to red hot, you're getting awfully close to melt temp of the aluminum.
I would heat the whole thing up to about 700 degrees (temp stick) and chill the bolt with a chunk of dry ice, because if you just use heat to swell and crush the bolt, the aluminum being weaker will be the part crushed, now you end up with oversize threads in your aluminum part.

 

Impact gun, as long as it's not set too high works really well because the stuttering vibration helps knock the corrosion loose.
candle wax melted into the hole, then heat the bolt works very well too.

If the head breaks off, then it's drill and easy outs. And when the easy out breaks - use this;
http://youtu.be/L4zohssWS7I

 

What about the wax process listed elsewhere on the HAMB?

 

Get the bolt hot and put a piece of bees wax on it, the heat will draw the bees wax down into the threads and it will come loose. Works for me 9 times out of 10.

 

That's freakin' awesome Don!

 

Lots of heat to expand the bolt, then allow to cool.

 

A nut welded to the bolt has never let me down,,,,, not once. I havent looked at an easy out in years.

 

It is a lot easier to weld a flat washer to the broken bolt then weld a nut to it. I do this on broken bolts has worked well.

 

Well I got them all out.........heat on the aluminum and welding nuts to the bolt......went through ten nuts getting them out.

I had one FU bolt. No matter what I did it wouldn't move. When I finally got it the P/O had broken one bolt off partway in the aluminum casting and just ran another one in there.......then broke it off at some point. What a pain...