Ok, so i searched around on here for a good tutorial. Didn't find one. Thought i would show how it is done with pictures. This could also be used to remove other bolts on your car as well. If you already took your trans out, i am pretty sure you are capable of doing this:

Tools Required:

1. Drill
2. Drill Bits
   1. 1/8
   2. 3/16
   3. 7/32
   4. 1/4
   5. 5/16
   6. 3/8
3. Propane Torch
4. Hammer
5. Impact Gun (Optional)
6. All i had for lube was pb blaster (Made it work lol),
   1. Make sure you have some kind of drill lube handy

The head of the fly wheel bolt measures right around a 1/4 of an inch so you don't have to drill too much deeper then that!



Some boagies and a beer might be useful as well

Torch:


Impact Gun:



And of Course Your Stuck Bolt on your fly wheel:

Before starting, align the bolt by cranking the crank with a half inch socket wrench to the most comfortable position for you.



Ok, Now it's time to start and drill this sucker out!

You want to put the smallest bit you have on your Drill. Start with the 1/8 bit.

Set your drill to low speed mode (Usually 1) at least on my dewalt. Also set it to drill mode. Put some lube onto your bit. Align your bit to the center of the bolt head. Start drilling Slowly! The trick to this is drilling at a nice steady slow pace. Only drill deep enough so your barley through the other side of the head of the bolt.



As you can see i already took care of the top bolt left bolt head.

Now after your first bit keep moving up in sizes. Make sure to stay in the middle of the bolt head. If you are off a little, don't worry just put your bit on a small angle into the opposite direction just to scrape off the excess. Then start drilling in a straight line again.



Keep going, Now since you are getting bigger in bit sizes, be sure to keep check the hole that you just drilled to make sure that you are not drilling into the flywheel or crank threads. ALWAYS double check around the whole inside of the bolt head. You will be able to tell immediately! If this happens stop drilling in the same direction and angle your bit so you are not drill on that side anymore.



Now i chose only to go to a 3/8ths bit because it's a tad smaller then the actually bolt. This gives you some play if you were to drill off center by accident. Once you get the hole size all the way through with a 3/8 bit. Start angling your drill to shave off the sides of the head. You don't have to do a whole lot more drilling at this point. Go Slow AND CHECK CONSTANTLY TO MAKE sure you are only drilling the bolt and nothing else.

Now for me after i thought i drilled enough and the head was thin enough to crack off. I began to Heat it up with the torch, get your flame inside the bolt so it really heats the threads up. Keep it there for a decent amount of time. After that hit it with the impact one more time. The second bolt i had actually came right out. This also will tend to make hair line cracks in the head of the bolt you just drilled. If you still have no luck, go at it with a hammer. And most likely it will pop right off.

If it still won't come loose use a slightly bigger sized bit or just continue to use your 3/8 bit to shave the sides of the head off from the hole while angling your drill.

You will end up with something like this as your end result:



After that take your fly wheel off. You will now have some area left on the bolt to unscrew it, mine came off by untwisting it with my hand! if not just get a pair of vice grips and grip onto the bolt and unscrew. You could also use some pb blaster and heat.

Hear are some end results of my bolts:









Just remember go slow and have patients!

If anyone else has tips feel free to chime in and i will add them onto this thread!

After you are done go have a beer and enjoy lol

 

Fixing pictures...

 

This just happened to me...worked great!!!

 

great writeup. this method works great for many applications. its the only way to go with subaru cam sprocket bolts.