I recently had a sheared off bolt on the ally SD1 engine. Only thing that did shift it was welding on a nut so the remains of the thread got cherry red with the heat. It then came out easily. So heat does work - but you'll need a lot of it. Likely so much you'd damage any paint finish. Otherwise it will be down to drilling it out.
(but most of the advice on seatposts is equally applicable to stems). With a stem you can (with many forks) hit it from underneath, which you can't with a seatpost (except with a Y-frame).
Yup, I did figure on some way of attaching my Bosch PMF-180 multi-tool and giving it a good old shake, but my friend had other chemical ideas....
... and succeeded! :-)
His was the repeated application of a very strong and hot caustic soda water solution, poured in the column and left to soak and drained out. A pretty dangerous activity.... kids don't try this at home yada yada...
According to him an awful lot of caustic soda was required to dissolve the aluminum enough to free it, as the stem had managed to chemically-bond to the steel fork steerer tube all the way down.
But thankfully no damage to the frame (apart from some of the paintwork) appears to have occurred during the three days of this treatment. These stem / tube things definitely need a good intercoating of grease ...
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