stuck header bolts

[Nuss]

and these Irwin bolt extractors are awesome!

Watch out for screw extractors though!!  I bought a nice set and it snapped flush when I was trying to drill and tap out the frontmost screw holding the cylinder to the head.  I went through a couple heavy duty bits on it which had no effect whatsoever.

[karatechop5000]

I would drill them out.  Small hole deep into the fastener.  Use several small bits and be prepared to burn the hell out of them.  At some point the friction of the drilling with a dull bit will loosen the fastener.  Pack a lunch.  Use a cheap drill motor.  Or whatever.  You probably got it already.

[JB848]

Nothing for nothing but I have lot's of experience in this. Everyone has their own methods and many have suggested good ideas to you. I worked on aluminium heads on VW's for 20 years plus and have had many results. If I could tell you anything it would be have a plan and be patient. When you get in a rush things go bad.

Liquid wrench the shiat out of it, have help when you are drilling into the stud..ergo have someone watch your angle to make sure you are drilling as perfect as possible without drilling into the head itself.

Now once you do get the easy out in you need to work it in and out, in and out, a 1/4 turn is a big gain with something that is stuck..so be patient! And one last thing is only use your wrist for power not your arm it's too much torque! Well good luck and let us know how you made out so others can learn from what you did?

[adidasguy]

Before drilling, try Eastwood's "Freeze-Off".
Penetrates, freezes and cracks rust to free up stuck parts. Designed for people restoring old cars.
Its worth a try before you start grinding and drilling things out.
Actually made by CRC industries   www.crcindustries.com  or order from eastwood.com

http://www.eastwood.com/crc-freez-off-super-penetrant.html

[JB848]

Bottom line is make a plan. Addiasguy has ideas I never have heard of so. I know in the day mine worked.