HELP..I'm stuck between a hard place and a hard place

[johnholt@halhinet.on.ca (John Holt)]

My Situation: I'm in a very rural location. The nearest Audi dealer is 60
miles away (just for reference). I have only one working car that is apart
as follows.  I was in the midst of changing my timing belt (102,000
kilometers and looks bad) and water pump. The belts, the timing covers and
the bumper are off the 1988 90Q. The crank nut and three of the four allen
bolts on the vibration damper are off.

My Problem: The allen key hole (6mm) in the fourth allen bolt on the
vibration damper is history. When I tried to remove it, it was evident that
it was re-installed with a slightly rounded hole rather than being replaced
by the Audi mechanic. My attempts to remove it were futile. The hole is now
completely round. I have used Liquid Wrench, impact driver, Visegrips,
etc., to no avail. The allen bolt is recessed between the vibration damper
and a raised area on which the crank bolt sits. Can hardly get a large pair
of Visegrips in there with almost no rotating movement to turn the bolt. Of
course, I have a number of obligations in the next week that require this
car.

Suggested Solution???

1. Pack it up and set off for the Audi dealer to remove the allen bolt.
That is definitely my last resort. This is the same dealer that created the
problem.

2. Use heat on the vibration damper. I'm concerned that the heat will fry
my timing belt which, as it stands, will allow me to continue to drive my Q
amnd meet my obligations. If I thought that frying the belt would
definitely remove the bolt, I would agree as I have the replacement belt.
My second concern is thet there is a rubber layer in the vibration damper
that may also fry and possibly require a new damper?? These are guesses.
Even with the heat, the bolt is round on the outside, round in the hole and
no side to side movement which equals zip in leverage.

3. Drill out the head on the allen bolt and slide off the vibration damper.
I'm not certain that this will work because I don't know, from lack of
experience in pulling the vibration damper, as to whether some of the
threads on the allen key would still hold the vibration damper. Doesn't
appear so. This is the best way I would think but if I'm wrong then the
vibration damper will be held my threads and I'll have no part of the bolt
showing to continue my quest.

4. I believe that the bolt is too tight to try easy-outs....my nemisis.
Only worked once.

5. Could make a slot in the head to use a straight screwdriver on the bolt
but due to the lack of room, I can't move a piece of hack saw blade side to
side to cut a slot. Also no room to use a small circular blade to cut the
slot.

I would appreciate any BTDT guidance.

Incidentally, I tried the crank bolt trick with a three foot extension to
my breaker bar and the starter but it wouldn't work. Then I went to a four
foot extension...still wouldn't work. They laughed but it does work with a
10 foot length of television tower.

John Holt
General Delivery
Highland Grove, Ontario, Canada
K0L 2A0