That is how I was able to walk the one below it out. I need a little bit of luck to get that initial movement then I think things will be fine.
Heat it with a propane torch and melt wax or a crayon into the cover around the bolt. I tried it at work once on an accessory bracket on a truck. It came out but who knows, it may have come out anyway after heating and beating.
It's out. The stud removal tool was able to spin it out of the block then I laid the cover face down on a pallet and drove the shaft back through the cover with a small punch.
Next adventure in the saga was discovered when I flipped the cover over to drive the stud out. Apparently last time the cover was off the PO must have stripped a water pump bolt. So he just drilled it through, I'm guessing to run a tap. Im thinking of having someone weld it shut as I don't like the idea of putting a bolt in and hoping it doesn't leak later.
Two steps forward, one step back. I've mentioned it before, you can use the low-temp aluminum welding rods for something like that. For $10 you can try it. If you aren't satisfied, that's not much lost. Aluminum low-temp welding rods
That's cheap enough to give the old college try. I'll clean the cover up good and pick some up this weekend.
Watch a youtube video or two to get a feel for it. Like soldering, you get the work hot, not the filler. The work melts the filler, not the flame.
Make sure it's very clean. You may need to screw a fastener in to make the hole blind.As the brazing alloy may just keep running through and not seal it off.
