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I found this issue in my car...
The engines previous mechanic had stripped one bolt on the install, and skipped at least one round of tightening, leading to a coolant to combustion chamber leak down the road. I got the motor from Pick n pull for $86, and ran it two years before the gasket failed.As i went to take it apart, i found the stripped bolt, and my tripple square tool spun freely. Grinding off the bolt top sounded no fun, so I went to the store and bought a brand new bit. Set the bit in place, found the best spline alignment, and beat the crap out of it with a 3 LB sledge, forcing the bit as deep as it could go, and hopefully loosening the bolt a bit as well. My impact wrench then removed the bolt no problem. If that fails, I would weld the bit into the stripped hole, the heat will also help to free the bolt. If you can break/file/dremell/die grind the head off the bolt, the threaded part will usualy come out pretty easily. It should be feasible to plunge cut the head off the bolt with an oxyacetylene torch if you are good at that kind of thing.
Don't those bolts make the darndest noise as they break loose? I use a 3/4" drive breaker bar with the handle of my floor jack as a 30" cheater bar.
Hope this helps
PS.
the cheapest (under$2) head bolts sometimes break before reaching torque, and, although I haven't seen one fail after installation, I don't recomend them
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