Tips for Removing a Stripped Flush Allen bolt
- Thread starter Jsf721
- Start date
jfleisher
Well-known member
Drill into it and use an Easy Out? https://en.wikipedia.org/wiki/Screw_extractor
Easy outs did not work this time. I will be ordering a new set as my set may be wearing out.
jrsavoie
Well-known member
This is what I would try.
Can you heat the surrounding area? After warming things up, squirt some Sea Foam on the allen screw and then try the left hand drill bit immediately there after. Work up in sizes from the first drill bit that will catch in the hole.
Maybe drill just a little with a bit that just fits in the hole without catching to create a center punch type mark.
Inserting a punch with a small enough tip to not get stuck in the allen and giving it a couple raps will not hurt anything either.
wssix99
Well-known member
I've had luck with getting a flat head screw driver; just the right size, and jamming it across the long part of the hexagon. Even in a stripped allen bolt, the flathead can't spin unless the thing is perfectly stripped out to a cylinder.
That Guy Scott
Well-known member
Tig weld a “nub” onto the head of it and then use vice grips. That’s how I do it.
zmotorsports
ALLIANCE MEMBER
^^Agreed. Or go one step further and weld a nut onto the head then use a wrench. I have done that many times with great success.
If you haven't already went to town on it with a drill then do This. Get a torx socket just a little bigger and hammer it in to the hole. Those hand held "impact" things work pretty good for this too if you have room to work.
Leaflessshadetree
Well-known member
I've been succesful using a sharp punch or chisel near the edge, just tap it counter clockwise.
Welding a nut on is also a good method, doesn't have to be TIG welded either.
Welding a nut on is also a good method, doesn't have to be TIG welded either.
nadogail
Well-known member
The services of a shop with an EDM Machine is your easiest solution; probably not cheap, but easy.
mike93lx
ALLIANCE MEMBER
Welding
That's my thoughts too. Depending on what it looks like, maybe weld in an allen key as an option.
KSJeff
Well-known member
I've hammered in Pipe ****** extractors before with great success. Like these:
https://www.harborfreight.com/5-piece-pipe-******-extractor-set-93822.html
BillK
Well-known member
Is there only one ? What is it holding ? Picture ? What size is it ? Lots of different ways to deal with it but a lot depends on what you are working on.
Wrench97
Well-known member
Drill out retap insert new bolt.
With countersunk heads like that l have had luck carefully drilling down just far enough with a drill bit the same diameter of the threads, to cut down to the threads and use a punch "rock back and forth" to snap the head off. Then use penetrating oil and an easy out to get the rest of it. Sometimes if you are using the right size drill bit, the head will snap off as you are drilling. Go slow.
Dumber than lumber
Well-known member
- Joined
- Dec 19, 2015
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Wow. An entire fambly of ‘em.
GJ bruthas rool!
GJ bruthas rool!
manwithtools
ALLIANCE MEMBER
I see you replaced with stainless, good move. Some anti-seize would help too.
Bretny
Well-known member
Gesus everyone's first go to for getting a stripped or broken bolt out is "drill it out"...well you never end up drilling exactly in the center and your removing what little is left to get a grip on.
WELD A NUT on it. It's still got a full head just nothing to grip...well add something you can grip.
WELD A NUT on it. It's still got a full head just nothing to grip...well add something you can grip.
This unit vibrates as it is operated. I have to use thread locker. the spec called for red but I used blue bc if I ever have to service it again i don't want to go through this process. I always use the best hardware I can get on my gear. The little extra expense is worth it on time and aggravation saved. Unfortunately the manufacturers don't think this way.
I want to learn to weld but sadly I am welder-less and don't have anyone to teach me even iof I had one. I would buy if I have a path to be taught so I could learn that skill.
Just now practicing sweating pipes LOL
Great Idea- I love this place-I usually hit it with the torch but the Iron is a better idea.
Floor sander ?
manwithtools
ALLIANCE MEMBER
Makes perfect sense, looks like a floor sander as Eric said...
Sander / Resurfacer depending on pad / chemical used.
I have used it on wood, and finished VCT and with a astro turf pad on tiles with grout.
driftpin
Well-known member
Plenty of good solutions described. For an inaccessible sides-of-(allen) bolt, in the last-case I faced (47 y.o. Honda SOHC 750-4), I elected to drill it. I went-up multiple sizes as it drilled-out, and finally I was able to back it-out. I believe heat and penetrating oil are the prep steps if an initial mechanical disassembly is thwarted.
