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This was taken a while back before I stuffed up the allen key head on the bolt. I have an dremel so maybe this might be the way to go with cutting a slot???

Well Ross, whatever method is used, careful process is needed.
You could try the slots first, not big fat wacken slots but carefully opposed slots to suit your fattest stanley screw driver. Vice grips applied to the screw driver will likely work.
If the bolt is too tight for that method, then an allen key tig welded (ideally) would be my next choice.

A surgeon with a mig will also be able to perform the operation.

Fingers crossed that the blot comes out easy.

I would put in a few drops of penetrating oil in and let it work for a while.
Then some gentle taps with hammer and punch.
Then cut the slot. Flat blade screwdriver with a bit of valve grinding paste for grip.
You can use the hammer taps on the end of the screwdriver as you try to turn it, or an air-impact wrench.
Failing that, I like Jeff's idea of an allen key spot welded.

dougie wrote:Failing that, I like Jeff's idea of an allen key spot welded.

What about my explosives idea?
No one ever seems to go for that option

At long last the alternator bolt is out. Screw extractor did the job. Thank you all for your advise.

ME 109 wrote:What about my explosives idea?
No one ever seems to go for that option

I'm not sure he was looking for a "Final Solution."

Major Softie wrote:

ME 109 wrote:What about my explosives idea?
No one ever seems to go for that option

I'm not sure he was looking for a "Final Solution."

http://www.metacafe.com/watch/223919/my ... ent_truck/

FUTURE wrote:The alternator rotor bolt. The one that I stripped the hex head of. Which way do you turn it to undo it? I know this sounds silly but for the life of me I can't remember.

righty tighty....lefty loosy