[quote=erice]i think you are talking about the anti-rotation bolt, as opposed to the 1 of the 4 beam securing bolts
if it is the anti-rotation bolt you have the choice of simply cleaning up the stub and then using stainless rivets to rivet the stainless strap to the alloy beam to prevent any rotation
however if it is 1 of the 4 securing bolts, or you'd rather something cleaner than the rivet solution read on
what's worked for me when removing a busted steel caliper bolt from an alloy bike fork is to
- buy a set of brand new drills and carefully drill it out, starting with the smallest, try and center as much as possible for later on, finish with the closest size to just under the busted bolt....while doing this you can try soaking the stub in wd40 type stuff and trying easyouts etc. but don't use enough force that you risk busting 1 those off in there! (otherwise it's spark erosion at a machine shop)
if it just won't budge and you'll drilled as much as you can without damaging the threads switch to a dremel and diamond bits to keep working away at the seized metal until the stub is so thin you can see the threads on the other side. then start picking out the bits with a sharp point[/quote]
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