Removing tough Allen bolts

[NDA]

I have a number of allen head bolts with a 2.5mm head to remove - two are proving impossible.

I don't particularly want to saw them off as they're on an expensive hi fi amplifier.

Here's a shot of one and the burred allen key:





Any thoughts on how best to remove them?

[BliarOut]

A) Buy better quality Allen Keys.
B) Use a dot punch to get them out.

[Odie]

Hammer a hex key larger than the hole into it

or use a hacksaw to cut a grove in it so you can use a large flat headed screw drive on it

or use an extractor like this set
http://www.screwfix.com/p/screw-extractor-set/1864...

Dont forget to order a replacement bolt for it if its still required.

[illmonkey]

You could glue the key in, let it set and try to get it out. Then just buy a new key and bolt. No damage done.

[NDA]

Thanks for the replies.....

I've ordered a better quality set of T Handled allen keys - so I'll try that first.

Glue might be an idea if that doesn't work. I'm assuming something stronger than super-glue?

Hammering and sawing is not really an option at the bolts are on the top of a rather expensive hi fi pre-amplifier.

[freecar]

You could araldite a cheap bit for a screwdrive in there, either allen shaped or anything that'll fit.

I use torx bits and hammer them home good!

[illmonkey]

NDA said:

Thanks for the replies.....

I've ordered a better quality set of T Handled allen keys - so I'll try that first.

Glue might be an idea if that doesn't work. I'm assuming something stronger than super-glue?

Hammering and sawing is not really an option at the bolts are on the top of a rather expensive hi fi pre-amplifier.

I recently glued a (car internal) door handle back together with some glue from the local car shop, £5 and apparently is good for 2300lbs of pressure... Think that should crack the bugger!

[XG332]

Just cut a slot and man up. I've done it a few times on our even more expensive race car.

[NDA]

XG332 said:

Just cut a slot and man up. I've done it a few times on our even more expensive race car.

Shan't.

I don't have the necessary hairy wedding vegetables to take a saw to the amp.

[SteveM46]

NDA said:

XG332 said:

Just cut a slot and man up. I've done it a few times on our even more expensive race car.

Shan't.

I don't have the necessary hairy wedding vegetables to take a saw to the amp.

Suggest you should open a vegetable gardening thread for this then...

[anonymous-user]

NDA said:

Shan't.

I don't have the necessary hairy wedding vegetables to take a saw to the amp.

Then get a grinder, every man has one

[NDA]

Dave_ST220 said:

NDA said:

Shan't.

I don't have the necessary hairy wedding vegetables to take a saw to the amp.

Then get a grinder, every man has one

I have a grinder.

It's staying in the garage. Out of harms way.

[netherfield]

You need an Oxy-Acetylene torch to warm it up first,that'll sort it out.

[anonymous-user]

On a serious note a flat blade will usually work, or, get some TORX bits as they bite into the mess you have made. Don't ask me how I know this.

[ColinM50]

Small grinding wheel in a Dremel and gently cut a slot it the head for a flat blade screwdriver.

I can't see how you're going to glue a torx or allen driver into it, surely the glue wont't structurally hold?

Can you phone the manufacturer and ask 'em to send you a handful of new bolts? Most would do that f.o.c. even for an out of date amplifier I'd have thought. Google for the Head Office and phone and ask for service dept, bet you'll find someone who'll pop half a dozen in a jiffy bag for you. Especially if you lay it on a bit, you know, how wonderful their amp is and what good service it's given and the sound quality and oh how you wish you could afford one of their latest xyz GT models etc etc. Betcha it works if you're greasy enough

[jas xjr]

You might be able to undo it with a pair of molegrips

[Simpo Two]

jas xjr said:

You might be able to undo it with a pair of molegrips

Good idea - much better mechanical advantage. Or those plumbing things. Protect the speaker from any scratches with masking tape.

[NDA]

I've tried pliers, the bolts are too small (2.5mm) for mole grips.

I'm not too worried about the replacements at this time.

I shall wait for the new Allen keys and go from there.

[jas xjr]

NDA said:

I've tried pliers, the bolts are too small (2.5mm) for mole grips.

I'm not too worried about the replacements at this time.

I shall wait for the new Allen keys and go from there.

You do know you can get smaller mole grips

[oniznorb]

ColinM50 said:

Small grinding wheel in a Dremel and gently cut a slot it the head for a flat blade screwdriver.

No! if it is an expensive amplifier make sure that any metallic particles from grinding or sawing are kept well away from it.