What are you guys doing to remove broken header bolts from aluminum heads? I'll be installing my LTs soon and want to be prepared with the right tools should I need remove any. My truck has about 40000 miles and I'm hoping the stock bolts with a good soak of penetrating oil the night before come out OK.

 

I had 3 with the heads broke off on my 100K mile engine and they came out easy enough with a pair of vise grips. The bolts don't really seem to get stuck in the aluminum heads like they do iron heads. If they aren't broken already I think you should be able to get them out just fine.

 

drill it out. Start off with a small bit and work your way up, and "try" to make it as straight as possible. Look for a bolt extractor kit. Usually it comes with a bit, and a tap that you hammer in. If you break the tap, your screwed. While you're drilling, use some WD40 or oil, anything but water to keep it cool.