There were numerous difficult bolts to remove when disassembling the rear cover on the SD20 saildrive. The worst were the two M10 bolts holding the rear cover to the saildrive leg.
This process ended up taking five hours to remove the last bolt, here is what was tried:
Note: Each removal was attempted after hammering a ball end Allen wrench in the bolt for 1 minute, then 30 second with an impact drill
1. Use a pick, small screwdriver, and a piece of safety wire in a drill to remove marine build up between the housing and the bolt (1 hour)
2. WD-40 spray, wait 30 minutes, attempt removal
3. Vinegar, wait 30 minutes, attempt removal
4. Penetrating oil, wait 30 minutes, attempt removal
5. Repeated steps 2-4
6. Fill plastic container with Barnacle buster and soak for two hours, attempt removal
7. Soaked overnight in penetrating oil, applied head with a blow torch to the head of the bolt, cool with ice, attempt removal
8. A piece of safety wire in a drill to clear debris, attempt removal
9. Cut off flange of rear cover on saildrive, attempt removal
10. Bolt came free
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