TLDR version: JB Weld Steel Stik saved my ass, job is finally done.
I'm back and...hell froze over and a miracle happened...at the same time LOL!
Since my brother still wasn't comfortable with his welding skills I decided to give it one more shot yesterday. At one point I had read about some kind of gel or grease with metal filings in it that was supposed to give the bit some kind of grip when you were working with a stripped or rounded out bolt. This got me thinking about JB weld steel stik. I thought that if I could maybe clean out the head and then JB weld the bit in, it just MIGHT give it enough grip for 1 or 2 more pulls. I took a curved pick tool and mirror and scratched out as much rust from the bolt head as possible. I then wire brushed it. I put a little bead of the steel stik putty on the end of the bolt and then pushed it into the head. I packed as much as I could all around the edges of the bit trying to push it down into the bolt head. After that set up, I made another ring around the bit.
It's supposed to fully cure in 1 hour, but I gave it an hour and a half to be sure. I put a 12mm box end wrench on it and wedged some wood blocks between the frame and the head of the bit. Got under it and gave it hell with a cheater bar...no good... wrench bent. THIS GAVE ME HOPE though becuase instead of stripping/flying out of the head, it meant I had another shot. Did the same thing again with a second wrench...bent again!
At this point, the edge of the JB weld was cracked free and the bit had a TINY bit of play in it...I figured I had one chance left. I took an old Craftsman gear wrench that I bought when Sears was still around and cut the open end off as a final sacrifice. This time, I went at it from the top. I had removed the coolant overflow bottle and had the AC line zip tied out of the way on the shock bolt. I ratcheted the wrench as much as I could towards the front, put the cheater pipe on and said a final prayer. I pushed that mother f'er as hard as I could towards the back of the vehicle and heard a big "crack"!!! At last...after almost a year later and maybe 8 attempts at this, that motherF***ing c***su*ki*g POS broke free!!!
Unbelievable, but I'm attaching pictures for proof. This had to be one of the worst jobs I've ever done on any vehicle. The only 2 other things that came close were replacing the heater core on a different 99 and replacing the exhaust manifold on this one 2 years ago.
Image 04 hosted in Freeimage.host
freeimage.host
Image 03 hosted in Freeimage.host
freeimage.host
Image 02 hosted in Freeimage.host
freeimage.host
Image 01 hosted in Freeimage.host
freeimage.host