I'm rebuilding the front forks on a F3 98' and powder coating the fork sliders. It's like two different people assembled each front fork. The first one came apart no problem. The Fork Bolt came right off with hardly any force. The second on the other hand is a different story. It's as if it was welded into place. During the course of trying to get the damn thing off I slipped and rounded it. I only made it worse. I have new Fork Bolts on the way but still need to get this one out. Any suggestions?

Thanks in advance

 

Get a set of screw extractors.

 

Dang, got a reply already. Was going to edit and add the fact that.... The bolt is 24mm so i've only seen sockets up to 19mm. My guess is that I made it almost 19mm from my butchering. Also a screw extractor type won't work because of the top of the damper. Ya a bit of a screw up!

 

pipe wrench

 

Don't know wot you mean by Fork Bolt, but if its wot I think your talking about (Top Bolt), steel screwed into an alloy thread, the corrosion you get forming around the thread is basically welding it into place.
You have two options, 1st on is to use a penetrating spray, a good size pair of multi grips (cause the hardened edge of the bolt is now R/S & will keep rounding out) With penetrating oil, you have to let it sit for a good while, I've had success with spray plus a rag soaked in oil tied around the bolt & left over night. 2nd option & more drastic, is the application of heat.