Stripped hex head bolt - removal?

[stickshift]

I have a partially stripped 7/32" socket head bolt (I stopped once the head started to deform). I found this video on removal, but wanted to check with GJ before I looked for a torx bit to tap into the head.

Before using a torx bit, would it be worth trying to impact it out with allen bit mated to an impact driver? Asking because I know impacting can sometimes jar fasteners loose where slowly (manually) applied torque fails.

Edit: Pic attached. Apologies for the confusion - I mistakenly referred to the bolt as a hex head when first posting.

 

[ItsNemo]

What size into what material holding what?

A little 2mm head into a toy is different than a 10mm head holding a suspension component.

 

[jdewitt]

^^^ What Nemo said.

That said, there's bunch of ways to remove bolts.... drill it, bolt extractor, cut a slot for flat screwdriver, heat, vice grips, weld a bar to it, etc. But it depends on the situation.

 

[matt_i]

I have a partially stripped 7/32" hex head bolt (I stopped once the head started to deform). I found this video on removal, but wanted to check with GJ before I looked for a torx bit to tap into the head.

No comprende here...how can you engage a hex head bolt with an internal torx driver....

That said, impacts, driver tools that have to be hammered onto/into the fastner's external or internal drive, the blue wrench (oxyacetylene torch), a LH drill bit.

But if they all fail it goes on my milling machine, the pilot hole straightened, the existing fastener cored out and the hole redrilled and the "lead" of the existing thread picked up to retap.

 

[stickshift]

What size into what material holding what?

A little 2mm head into a toy is different than a 10mm head holding a suspension component.

7/32" head going into a what I believe is a steel pivot pin. The other side of the pivot pin also has a 7/32" head threaded into it. So I need two 7/32" allen keys to remove the pivot pin.

 

[turbowoodworker]

Pictures? Sounds a little like a shoulder bolt?

 

[signcrafter]

Astro used to make some special Allen head bolt removers that had a two piece cam head that would grip them when they stripped out. I believe they stopped making them. I have a set and luckily never had to use them.

 

[ItsNemo]

7/32" head going into a what I believe is a steel pivot pin. The other side of the pivot pin also has a 7/32" head threaded into it. So I need two 7/32" allen keys to remove the pivot pin.

Pictures? Sounds a little like a shoulder bolt?

Agree, pics?

7/32" head going into a what I believe is a steel pivot pin. The other side of the pivot pin also has a 7/32" head threaded into it. So I need two 7/32" allen keys to remove the pivot pin.

That doesn't sound too big, I'd be liable to try vise grips first if the heads aren't recessed.

 

[jdewitt]

I have a partially stripped 7/32" hex head bolt

So I need two 7/32" allen keys to remove the pivot pin.

So is it a hex head or socket head?

 

[PoorOwner]

You can try JB weld the socket / hex key and try again tomorrow.

If you can grab with a vise grip then it should be easy.

Impact it will usually round it off further.

 

[joe_padavano]

No comprende here...how can you engage a hex head bolt with an internal torx driver....

Um, with an EXTERNAL Torx socket?

 

[Ign]

So is it a hex head or socket head?

If he's talking jamming Torx in it it's socket head and he's confused because it takes a hex key.

OP a hex head is literally that: the head IS a hex (on the OD)

 

[jhnlngn]

Sounds like he means a socket head. Not going to get very far using an "allen key" on a hex head.

 

[Ign]

Anyway, the Astro set has promise but only available in metric, or search Sock-It-Out. Or LH drill bits

 

[Professional Tool User]

I would avoid impacting an already messed up hex screw or bolt unless this is with an manual impact driver. It will probably make it worse. First thing I would do is see if there's a slightly bigger metric size hex bit or socket that will get it moving or use a vice grip. If not, there are those special hex keys with an extractor on one end for messed up hex screws. If you happen to have a welder, you can weld a nut on and put a socket or wrench on the nut.

 

[Spacey_G]

You might have luck with a Wera hex plus key. I have personal experience removing socket screws with those where a regular hex key just spun.

 

[bob15]

 

[Gurp]

+1 on hammering a torx into it. Heat the bolt first to expand the metal then hammer the torx socket in amd let it cool. Ive had to do it on brakes someone stuck a wrong bolt in before.

 

[paulsomlo]

From his comments and the video, it appears he's dealing with a socket head cap screw w/internal hex.

You don't say whether the head sits in a counterbore, or not. If so, you have less options. If the assembly will allow for it, place a punch in the head of the fastener and give it a couple of wacks with a hammer - sometimes you'll loosen any corrosion between threads. If it's in a counterbore and all else fails, you may as well use the impact, because you're next option is probably drilling it out.

If it's not in a counterbore, use an extractor socket - you'll chew up the head though.

 

[KnurledNut]

Sure its not 6mm?

 

[bowtech321]

Mac tools came out with a set of sockets for striped out hex. Seen a set on the truck they look nice. I haven’t tried them yet. But will probably buy the set to have


Sent from my iPhone using Tapatalk

 

[ex-x-fire]

I'd cut a slot in it and use a screwdriver.

 

[stickshift]

Sorry guys, I used incorrect terminology, creating some confusion; it's not a hex head.

I don't think corrosion is an issue; equipment was stored indoors and all the bolts I removed have nice clean threads.

 

[stickshift]

Sure its not 6mm?

Yeah. Service manual gives sizes and all the fasteners are SAE.

 

[CJM8515]

pipe ****** extractor after you drill it out a bit https://www.homedepot.com/p/Husky-6-Piece-Pipe-******-Extractor-Set-80-533-111/304341668

 

[PoorOwner]

pipe ****** extractor after you drill it out a bit https://www.homedepot.com/p/Husky-6-Piece-Pipe-******-Extractor-Set-80-533-111/304341668

That looks great.. didn't know they make that.... I would want to have this in the toolbox to get things out of a bind some day.

it's like wheel lock remove socket but reversed.

 

[bob15]

Weld a bolt or nut on it and screw it out

 

[CJM8515]

That looks great.. didn't know they make that.... I would want to have this in the toolbox to get things out of a bind some day.

it's like wheel lock remove socket but reversed.

I just used my set the other day for EXACTLY the same scenario the OP has. I drilled into the bolt about 1/2" and smacked that sucker home and the bolt came right out. The hex had stripped right out using the proper sized bit socket as well.

 

[Millwrong]

Sorry guys, I used incorrect terminology, creating some confusion; it's not a hex head.

I don't think corrosion is an issue; equipment was stored indoors and all the bolts I removed have nice clean threads.

What exactly are we looking at? Can you not just put some vice grips around the entire head of whatever that is?

 

[PassnThru]

Looks like you have plenty of room to put a chisel or air hammer on the outer flange to get it moving.

 

[sberry]

If I wanted to be neat here would grind or saw a slot across it. It had a dry thread and got stuck when it was installed.

 

[stickshift]

Weld a bolt or nut on it and screw it out

No welder, unfortunately.

 

[stickshift]

What exactly are we looking at? Can you not just put some vice grips around the entire head of whatever that is?

Fasteners on cardio equipment similar to an elliptical.

That outer piece is separate from the bolt (tried with vise grips and I can spin it separately from the bolt).

There are 4 of these pivot pins and they all consist of the pivot pin and 7/32 Allen head bolts on either end. I just checked the other 3, and they are all so tight that torque sufficient to loosen them will deform the Allen heads. Seems the manufacturer over-torqued these fasteners assuming they'd never be removed.

 

[stickshift]

Looks like you have plenty of room to put a chisel or air hammer on the outer flange to get it moving.

That outer flange is essentially a washer, it's separate from the bolt.

 

[stickshift]

So here's a similar part - a pivot pin with a 7/32 allen head bolt on either end. This pivot pin runs inside bearings.

I've got 4 of these pivot pins where the 7/32 allen bolts on either side are too tight to loosen without stripping the head. So whatever solution I use on one side, I'll also need to use on the other, because if I can turn one side, with just a 7/32 allen wrench on the other side, that allen head will probably strip.

The large washer/flange is securing some plastic housing. So once the bolts are removed, the plastic housing can be slipped off, and the pivot pin pushed out of the bearings.

 

[Spacey_G]

Have you considered replacing these with regular socket head screws once you do get them out? You'd jump up to a 5/16" hex wrench and get a deeper socket too.

This is classic button head behavior, between the smaller tool and shallow socket.

 

[PoorOwner]

They might have some sort of loctite on it, pretty common on exercise equipment.

Allen bolts everywhere but they feel like they are made of cheese.

 

[Spacey_G]

Allen bolts everywhere but they feel like they are made of cheese.

They probably use stainless hardware for when the workouts get real sweaty.

 

[stickshift]

They might have some sort of loctite on it, pretty common on exercise equipment.

Allen bolts everywhere but they feel like they are made of cheese.

That must be it!

Let me grab my heat gun. BRB.

 

[Clcartagena89]

I personally would use a cut off wheel and make a slot and use a flat head, but drill it out if you want and should just fall apart on you.