Rusted bolts are a pain to remove, and trying to get out a rusted Allen bolt is even tougher. Unfortunately, you'll probably loose the bolt in the process, but if you do it right, you can get the bolt out and replace it with one in better condition.
Instructions
1. Spray penetrating oil onto the rusty bolt and if you can access it, the nut holding it in place. Let this soak for a day then do it again.
2. Attempt to remove the bolt using the Allen key set. If the bolt doesn't come out, move forward to the next step.
3. Cut a line into the center of the bolt using the die grinder with cut-off wheel. You're going to be making a slot for the flathead screwdriver to be inserted, so keep that in mind and be careful not to hit the surrounding metal.
4. Place the screwdriver inside of the slot and try to turn it counter-clockwise. If the bolt still doesn't come out, move to the next step.
5. Drill a small hole in the center of the bolt using the drill and metal drill bits. You want to drill a small starter hole so you can use the extractor.
6. Insert the screw extractor into the drill and then into the hole you just drilled. Turn the drill and try to remove the bolt. If it doesn't come out, move on to the next step.
7. Drill out the bolt using progressively larger drill bits. This will destroy the screw completely and allow you to knock it out.
8. Run a tap through the screw hole to clean up the threads. The bolt is now removed.
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