Thanks R6Philly. The metal file/11mm idea is great. Will try that first.
Here is what I have so far:
1.) Get wife try to help me get the wheel back on, then take it to a pro.
2.) Use a metal file to create flat spots back on bolt. File down to 11mm. Use impact wrench. Pick up air compressor from Walmart for $20.
3.) Try hammer & chisel, striking the head of the bolt in the counter clockwise direction.
4.) Take a propane torch and heat the head of the bolt of for a minute or so. Keep in mind that this heat is going to transfer to the fork so don't get carried away.
Next let it cool down. The expansion and contraction MAY break the bolt loose. Spray a good penetrating oil on the bolt from both ends being careful not to get any on the pads.
Next tap the head of the bolt sharply with a small ball peen hammer to shock the threads a little. What you want here is a sharp smack, NOT a hard hit!
Put the vice grips on TIGHT! I mean eyes bulging out of your head thinking these things are NOT gonna close tight!
Hopefully you will be able to crank the bolt out at this point.
If it still won't come out, heat it back up and try removing it hot, again being careful not to get teh fork too hot. I'd put your hand on teh fork leg a couple inches above the bolt and if it starts getting uncomfortably warm, STOP!!!
5.) Try a different screw extractor from Ronnie or Sears.
6.) Step up drill bits, removing the screw material. Use same size tap & die to clean out the threds.
