Welding to header bolt. Safety pointers needed

[1_v8_merc]

Be careful with EZ Outs...if they snap, you're screwed.(unless you get lucky)
They are good for simple clean extraction areas, but in tricky stubborn areas, you're begging for trouble.
I think you need titanium bits or something harder to drill threw it, if EZ-Out gets lodged in there?

You could just drill the screw out, with metal bits.(slowly Upping your drill-bit size) But make sure you have a TapKit on hand, because you might need to re-thread....not a big deal, but if you're not mechanically inclined, you might just wanna pay someone to drill it out, and re-tap it for ya.

 

[Normk]

JohnT, it is usually easier to free seized fasteners from aluminum than from cast iron or steel by heating because the aluminum spreads away from the heated fastener more easily. The trick is rapid heating of the fastener in order that it expands rapidly to stretch the aluminum rather than providing time for the aluminum to also heat. The lower tensile strength will allow the heated steel fastener to expand the hole and so result in a loose fit when cool.