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Old 10-03-2012
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Re: Advice on removing snapped s/s bolts from alu block

Sailordave has it right, except MAPP fuel may be necessary if the aluminum carries too much heat away. YOu want to get it pretty toasty and spray the PBbuster on while it's hot and the quick shrinkage can create more crevice between the bolt and threads. Also, the center punch is necessary which can also shock the bond between the threads. Lastly, there is a impact driver that will transfer hammer blows into rotation and doesn't cost much to try. You'd have to chisel a flat head slot to get a grip. Heat, cool, shock, repeat. IT will come out.
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