Drill & tap !  That's the only dance that will succeed in this situation.

On 2012-05-22, at 12:00 AM, Automatic digest processor wrote:

> I recently removed the waterpump and thermostat housing from my
> 1984 vanagon only to find the gasket between the hose flange and
> the housing to be bulging and leaking.  When I attempted to remove
> one of the 6mm bolts, I broke the head off the bolt.  I thought my
> only option now was to break off the other bolt head, remove the
> hose flange, remove the gasket, and soak the threads with Sea Foam.
> I applied Sea Foam twice a day for a week.  I thought now the bolts
> may move slightly so make more paths for the penetrating oil.  I
> put a small vise-grip on the bolt stub but the bolt did _not_ move.
> I do not want to apply so much torque to twist off the bolt stub.

Cheers,    

Frank Condelli
Almonte, Ontario, Canada
'87 VW Westy, '00 Kawasaki 250 Sherpa, "98 Ducati 750 Monster & Lionel Trains (Collection for sale)
Frank Condelli & Associates - Vanagon/Vanagon Westfalia Service in the Ottawa Valley
Vanagon Stainless Steel Exhaust Systems
BusFusion a VW Camper camping event, Almonte, ON, June 07 ~ 10, 2012