I agree with the suggestion to use heat. Aluminum's coefficient of expansion is 2 to 2.5 times that of steel. A propane torch is the tool to use. If it was assembled with the high-temp loctite the heat will also break that loose. I have also had luck "shocking" a broken bolt out. Drill all the way through the bolt as you have done and fill the hole to the top with penetrating oil. Let it sit overnight--this will allow the oil to work its way up the threads from below. Then, drill a second small hole as close to the edge of the broken bolt as possible. This hole should be drilled to a depth about equal to its own diameter--just a dimple, really. Then, put a nail set in this hole/dimple, angling it to drive the broken bolt counter clockwise. Give it a good sharp "pop" with a hammer and the bolt should hopefully shift a little bit in its hole. Once it starts to go, the oil will seep in all around it and help things a lot, and you should be able to work it out by repeated sharp hammer blows. The shock trick may be hard here as this bolt sounds pretty small. I used it on a frozen sheared off radiator housing but that one was 3/8. I drilled through with a 1/8 drill bit, then made my dimple with the same drill bit as close to the edge as I could. I also used it on frozen bolts in aluminum magneto housings where I couldn't use heat for fear of ruining the magnets, and it worked great. As the others have said, you do have to let the oil work overnight or longer if you can, which is hard for me as I am impatient on these things. Good luck.
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Today's Featured Article - Earthmaster Project Progress Just a little update on my Earthmaster......it's back from the dead! I pulled the head, and soaked the stuck valves with mystery oil overnight, re-installed the head, and bingo, the compression returned. But alas, my carb foiled me again, it would fire a second then flood out. After numerous dead ends for a replacement carb, I went to work fixing mine.I soldered new floats on the float arm, they came from an old motorcycle carb, replaced the packing on the throttle shaft with o-rings, cut new ga
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