Outboard Motor toggle bolts frozen

[danielamartindm]

It happens. Here is what worked for me.
First off, abandon any thoughts of brute force. Those plastic toggles weren't meant for anything stronger than hands, and you'll just snap them off.

Some recommend bathing the bolts and housing overnight in 50:50 acetone/transmission fluid. I suspect this would work quite well if you're in the secure environment of a workshop or garage, not "in the field" as I was.

The key is patience, penetrants, vibration, and heat, with emphasis on patience. (Use common sense about heat and the potential for hydrocarbon aerosols to ignite).

First, spray both ends of the bolt with FreezeOff penetrant. It not only contains a penetrant to help dissolve corrosion, but it's a refrigerant that will take advantage of the differing coefficients of thermal expansion of the bolt and its housing. Allow it to evaporate. Then, using a torch rated for high heat, heat the bolt and its housing. Then apply force to the toggle with manual torquing pressure and give the bolt a tap with a hammer. Repeat this procedure; and as the bolt starts to loosen, you'll be able to turn the toggle to greater arcs until it is finally what you want it to be, a lubricated bolt capable of hand-tightening throughout its threaded length.