[norwaypinesavage]

The three best chemicals are PB Blaster, PB Blaster, and PB Blaster. Don't listen to anything else. I've been removing rusty bolts for more than half a century, and you've ruled out the only thing better - the heat wrench (oxy-acetylene torches).

Actually, an electric heat gun will help a lot, too. Use a real heat gun, not a hair dryer. You can buy one from Harbor Freight for around ten bucks. The coefficient of thermal expansion of aluminum is nearly double that of steel, so a good warmup will expand the aluminum around the steel and help a lot.

The problem with rusty bolts is that rust is steel that is combined with oxygen. Therefore, it has more volume than the original steel. The extra volume fills in the gaps and actually tightens the bolt. That's why heating it, which expands it, helps so much.

[Windflier]

The three best chemicals are PB Blaster, PB Blaster, and PB Blaster.

Sounds like a pretty strong product endorsement ;-)

Actually, an electric heat gun will help a lot, too. Use a real heat gun, not a hair dryer. You can buy one from Harbor Freight for around ten bucks. The coefficient of thermal expansion of aluminum is nearly double that of steel, so a good warmup will expand the aluminum around the steel and help a lot.

I can do ten bucks for a heat gun. I'm reluctant to use my propane torch because of the nearby neoprene rollers.

Thanks!