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Use a small drill to carefully drill out the center of the bolt. Then use a tap to clean out the rest.
I would get a set of reverse rotation drill bits (some call them left handed) that drill while turning counter clock wise. Drill the bolt with those, starting small and working up a bit (careful not to get into the threaded area). Often, as you remove the center of the bolt, and get near the end of it, the remainder of the bolt will unscrew it’s self for you.
+1 to the above suggestions. If you get off center drilling out the bolt, you can correct with a die grinder fitted with a shallow tapered bit. Coat the bit with bees wax to cut aluminium. This prevents the bit from becoming fouled with the soft aluminium.
ouch, aluminum and steel just don’t mix and I will never understand why manufacturers keep doing it.
One of the worst jobs I ever did was a rear evaporator core in a suburban, steel lines, aluminum fittings :blink: . Even though I warned the customer ahead of time that lines would most likely have to be replaced also, he was quite mad when the aluminum fitting left it’s threads attached tot he steel line.
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