This is why we dont use steel and alum together!!!  These are Warn Hubs I was trying to remove.  All bolts snapped off and each hole is cracked.  I did not even have a chance to beat on the hubs. I am parting this Tracker out. You should see what she is like!!  

WOW that looks pretty rough.

I doubt a week or two of penetrating fluid followed by some heat and an impact would even have made a difference.(but thats what I'd have tried)

Is that really split all the way thru or is it just on the edge? I guess it doesnt matter it's still pretty rough.

Lack of maintenence can ruin any materials.

When I worked on concrete trucks the newer ones came with alluminum rims and still had the cast hubs so there was a corrosion problem that if left to itself would make for some serious work just to get the tire off to be changed.

We would clean(wire brush) the mating surfaces of the rim and hub and then coat it with an aluminum anti-seize compound and after that the tires would pop off with just a sledge hammer hit.

It works well but I doubt many people would actually do it unless they had the hub off for some reason.

There is rust in every spot possible on this thing.

I use nickle anti seize compound on every nut, bolt and fastener on my Tracker, at least the ones that don't require thread lock compound. They come off easy, and make maintenence much less of a chore.   

Hmmm, the way the hub holes are split, it almost looks like the PO used the cone washers with the warn hubs (which I am pretty sure just have straight cut holes, not tapered holes like in stock trackick hubs).  Otherwise, I can't really see how straight bolts with no cone washers would cause all the holes to split out like that.

This should be every ones friend on here

This should be every ones friend on here

Amen

this what makes me nervous when i start doing the 1.6 motor swap. the header bolts are heavily rusted

Start soaking them now with some PB Blaster. 

this what makes me nervous when i start doing the 1.6 motor swap. the header bolts are heavily rusted

If they twist off, just take a nut and place over the twisted off bolt, fill the nut full of weld (concentrating the weld on the end of the bolt), let it cool off a little, and the heat from the weld should loosen up the bolt, so you can just turn the nut and the twisted off bolt will come out with it.  I've removed a lot of twisted off bolts this way.....everything from wheel hub bolts to tcase bolts.
This method works much better (and faster) for me than trying to drill out and use screw/bolt extractors (ez-outs).