DON'T HEAT THE STUD! That will make the situation WORSE. You need to have the stud COOLER than the surrounding aluminum. That's why you spray it with WD-40 - to cool it and make it SHRINK. -- Mike > What are you using for heat? Propane probably not hot enough -- need > acetylene. Not really a process for novice (which I am w/ gas welders > BTW. Took my car to a professional). Essentially you heat stud until > it becomes slightly molten, then remove as quickly as possible. > Potential problem: can heat stud too much so it melts into threads and > becomes totally unremovable. >