What to do if you round a Torx Socket bolt VB#6 and Tips for removing seized bolts!

Seized bolts - gotta love em..no, that's not right!? And a common after affect of a seized bolt: Rounded Heads! Once it gets to that point - your options become more complicated, or wishing you had that special set of sockets from Irwin:

The "Bugger I rounded it" kit!

Well had my own run in with one today and the worst kind of bolt to round: The Torx Socket Head!(Dum-Dum-DUUUUMMMM!)

Look at the Evil little bastard!

Prior to rounding, I tried every trick in the book, in order:

1. WD40 or GT85 - both are good penetrating fluids (AND NOT LUBRICANTS!) - spray liberally on the affected bolt/nut, then got to town on it.
2. Hammer Time - Twat the thing the bolt is fasten in first and if that's not possible, twat the head of the bolt, you can maximise the effect by using a drift or another bolt. Works good on track rod ends too - hit the bit the end sits in and no the end itself, wind a nut on too the protect the threads. The idea is to shock the affected area, releasing the rust/bonding hold the bolt in place. Using an anvil (like another hammer) can also help.
3. Make an Impact - if you have access to an impact driver, USE IT. It hammers and turns at the same time, don't be a hero and put your back out when you can let the tool do the work for you!
4. More Leverage - Even impact drivers can match the torque of simple leverage! Get a long cheater/breaker bar and hang off it or you can use the double spanner trick, this is dangerous though. Thanks to +Ultimate Handyman :

I'd be a bit careful with this one - it may feel like its budging but be warned, you could be shearing the bolt! If it won't budge using the longest bar with you on the end of it, STOP or else you'll be finding a bolt extractor!
 
4. Fire -  This one I would suggest you do last as by now the penetrating fluid may have evaporated by now and not much pose a fire hazard. ALSO ITS BLOODY DANGEROUS! Clear away anything flammable and watch where you pointing the flame, assess what's in the region where your heating up: fuel lines, brake lines, rubber parts, etc. The heat expands the nut or bolt thus releasing the bonding, usually quite effective, but as before, use caution! A propane or butane blow torch is good. If you have access to acetylene, then you probably know this trick, but if its your first time doing this, then I'd put the gas axe down for now and get the brule torch out!

I decided to fill in the rounded hole with weld so I could use my bolt extractor set. Went to drill the hole, got the the weld but the bit wouldn't go through the shaft of the bolt! So my drill bits aren't up to it, scrap that idea!

welded up hole!

I then decided to weld an M8 bolt head to the bolt and then wind a nut onto the bolt and weld that to the bolt too, then take an impact driver and run it till it shifted. FINALLY; it moved - "um why so short.....?":

Yep the Damn thing sheared! SO now I have to figure out how I'm gonna get that out.

Pissed off doesn't cut it!

Seriously who the hell chooses these fasteners? why Torx? why not recess the hole and use a low profile hex head? FFS!