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This is one of those dumb questions that I ask every so often
How do you get a rounded of exhaust manifold bolt out? I have tried all that I have thought of Vise grips, mm sized bolts, pipe wrench (was bronze so it didnt do much). I am out of ideas and the bolt is still in the manifold
Try to borrow someone's "Metwrench", these are supposed to work even on rounded off bolts. (These sockets work off of the SIDES of the bolt head, not the corners, which do round off.) You might check at Sears, believe they might sell these kind of sockets, but not sure. Suppose as a very last resort you could try to cut the head of the bolt off with an air chissel, or something like that.
From: At my Bar drinking and wrenching in Lafayette Colorado
Re: Rounded head bolt (ZD75blue)
If all else fails, remove all the other bolts, and then grind the head off of the damaged one. You can thus get the manifold off. Once the tension is gone from the bolt and the manifold is removed, you can then get the remaining bolt stud out of the head fairly easily with vise grips or a stud remover provided it is not corroded into the head.
I seem to recall previous posts that suggested using a dremel to cut a screw driver slot in the head and try to get it out with a big screwdriver. If that tears up the head you could always still go with the "remove the (whole) head" approach.
I know I'm stating the obvious, but you have soaked that puppy with penetrating fluid, right?