Sway bar link allen nut stripped

I'm not seeing the stripped 6mm hex in this pic? You sure you have the right pic? Or are you saying the hex / allen key broke off in it?

There's a bunch of techniques to do this but I've not worked on this part of the car yet and can't see it clearly... Welding some metal into the hex socket is one way?

Another thing I saw on Tik Tok that I want to try is heating the nut up with a torch and then using candle wax to penetrate the thread and unbolting before the wax cools off.

Penetrating oil of course is what most will use. But still no clear on what you mean with "6mm hex in the center"

 

I've never seen what's under the boot so I'm not sure this works on the prius sway link.
You're probably gonna need a new one anyway so get that squared away and if you don't want to cut you can grab what's under the boot with vise grips. If the vise grips hold turn the nut back and forth to clean the rest of the threads as you remove the nut. Next time clean the stud threads completely before trying to remove the nut.
Or a nut splitter for $9 at https://www.tractorsupply.com/?cm_sp=Header_Nav-_-Links-_-Logo

 

as far as the pic is concerned? looks like maybe it happened long time ago?

I'd say go with what you mentioned and just remove what you can and replace w new.

 

If you watch some youtubes about how the pros remove wheel locks without a key they may give you some ideas about how to jam something into the rounded off hex socket to hold it while you spin the nut the rest of the way off.
Heat doesn't really work to well on links, the heated grease under the boot heats up and the ball spins faster than when it normal temp. You might get lucky though.

You can get better nut crackers than the pair Tractor Supply sells but most are at least twice what Tractor Supply wants. Some will cut both sides of the nut. If you use the nut splitter right it's possible to peal the nut of the stud without buggering the stud threads.

Not sure where the problem is on the links stud if you can turn the nut by hand put can't get the nut off the stud. Im guessing but I'll keep my guesses to myself until you indicate whats going on with it.

 

That will happen if you are using a crappy harbor freight type quality tool.
Have to use a name brand like craftsman.
I would have hit that with some Pb blaster let it sit for a few days.

Looks like you have significant rust under there.
Go to Home Depot and buy some spray cans of grease called CSP SPRAY
made by PB BLASTER but does not stink.
Spray the crap out of all the suspension parts that move and bolt heads it will mitigate the rust a little.
Get under the back of the car check the springs they are known to break when severely rusted hose that down too.

CSP spray is a great product use it on the front hood latch and all the doir and hatch hinges spray it in the keyhole of the front drivers side door and gently work that lock back and forth.
Many a Prius owner found that locked rusted and could not get in the car when the 12 volt battery died.
Front hood latch will fail too and can’t get in the engine compartment.

 

I have good results by soaking it down with PB, and use a high power impact wrench to unbolt it.. good luck!

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Wow that exactly what I would have used I dig the freeze spray trick that works.
Really good job there.

 

But how will you stop the bolt/stud from turning when you are tightening the new nut?

 

If you have the sway link out, you could try making a straight cut (slot for a large flat screwdriver) across the stripped hex hole. It's kinda iffy though cause of the hollow hex hole making it a weak slot.

 

If a 1/4" key is too big, try grinding one down a hair. Not like that's a rare size.