In my daily work at the motorcycleworkshop I have this issue all day, every day.
Sometimes it is a battle, but I never loose.
These are some options:
-Spray penetration oil, (Sorry, wd40 does little) and leave it a night over
-Startle the bolt with a hammer, it cracks the rust
-Heat: torch, paintstripper, acetyleneburner. Does the trick most of the time
-Weld a big nut on the bolt and unscrew with the nut.
-Drill the bolt out and freshen the tread with a tap.
-Send it to me, I'll fix it
-Last: buy a new one
Herman
another tip: If the hex is worn: dip the wrench in some grainy stuff, we use valve polishing paste. It give the wrench grip again.
yet another tip: This kind of trouble is often started with a worn or cheap wrench. These rip the hex out easily. Pass the 2 dollar set at the mall!
At work I use a set for 15 years now, every day. The wrenches are not worn, they don't even show a scratch. Top notch, these Swiss PB lads:
If you can find them in the States, give them a try:
http://www.pbswisstools.com/en/quality- ... nches.html