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.

I tried turning clockwise. Nothing.

I tried turning counter-clockwise. Nothing.

I tried freezing the entire housing with the vise-grip attached and
then heating just the aluminum housing around the bolt with a propane
torch.  No movement.

I tried many small impact taps on the bolt stub. No movement.

I read on-line somewhere three important steps when removing seized bolts:
1) Be patient.
2) Be very patient.
3) Be extremely patient.

My next trick is to spray the bolt with super coolant to make it
contract.  I assume the local napa will have something environmentally
friendly.

What am I forgetting?
I am open to any and all suggestions to remove the seized bolts.

Does anyone have a spare used water pump thermostat housing laying
around you want to sell?

Attached is a photo of my poor tortured housing.

--
William
grateful@nmia.com

505 440 0760

Too many people spend money they haven't earned, to buy things they
don't want, to impress people they don't like.
-Will Rogers