How to remove a rounded off bolt in a awkward position?

[1083 Feedbacks]

Im trying to remove a non serviceable ECU attached to my steering column.

The bolts to remove it at at the top of the column behind the steering wheel. I've dropped the steering column and its currently resting on the driver seat.The bolt thats rounded off is not viewable by eye, it is in the most tight, deep position ever and im literally may as well be blind folded when trying to get the torx bit on it.

Anyway. One has rounded off. So i cannot hammer anything on it (no room), cannot weld anything to it (no room). And cannot drill it. No room.

I've tried ABRO STEEL with no luck.

Hoping someone on here could advise what else i could use to get it off?. Those gator grip sockets wont work, the gap is far too small to get a socket down on it. I read JB weld could be a possibility. Never used it, but looking on youtube i can see its not as strong as made out to be.

The rounded off torx i need to remove is also annoyingly glued in with loctite thread lock, i know this as i've taken out one of the bolts already without rounding it off.

EDIT: heres some pictures:

This is the ECU i need to remove:
https://i.imgur.com/Bq9YEnS.jpg

1. steering column dropped:
https://i.imgur.com/eNQir4x.jpg

2. going under the dash
https://i.imgur.com/2KyFJZg.jpg

3. First glimpse of the culprit torx screw
https://i.imgur.com/BaS5tNX.jpg

4. In all its glory
https://i.imgur.com/lUOndRe.jpg

Edited by 1083 Feedbacks on Monday 30th October 12:47

[N Dentressangle]

1083 Feedbacks said:

The rounded off torx i need to remove is also annoyingly glued in with loctite thread lock, i know this as i've taken out one of the bolts already without rounding it off.

It'll probably need heating then in order to break that bond before you can remove it.

What's the car? I'm guessing you've google 'how to remove x from x'?

[1083 Feedbacks]

TVR Moneypit said:

I'm sure you've thought of this, but is there room to cut it off?

Its impossible. Not even a dremel will reach it. Its in under the dash and down 6 inches with metal either side of it leaving a small gap only a screw driver can fit down to reach the torx bit.

[bern]

Could you get in with a dremel type tool with a carbide burr on and grind the head off?

[1083 Feedbacks]

N Dentressangle said:

1083 Feedbacks said:

The rounded off torx i need to remove is also annoyingly glued in with loctite thread lock, i know this as i've taken out one of the bolts already without rounding it off.

It'll probably need heating then in order to break that bond before you can remove it.

What's the car? I'm guessing you've google 'how to remove x from x'?

Its a Q7 but there is no point explaining what im trying to do as i doubt nobody has heard of the fix. Audi say its non serviceable and therefore a £2500/£3000 job to replace the whole entire column. However i know the ECU is serviceable as i've done one before, the fix is £10 if you can remove the darn thing!.

The best way i can describe the location of the torx is, if you can imagine trying to go down your sink hole to reach the torx bit on a the U bend.

[finlo]

Extra long drill bit?

[steveo3002]

yeah any scope to cut holes or cut it in 2 then re weld /repair afterwards

[1083 Feedbacks]

finlo said:

Extra long drill bit?

Cant get a drill in there. Not even a dremel will fit.

[1083 Feedbacks]

TVR Moneypit said:

This is a bit of a desperate solution, but can you cut off the metal surrounding the torx in order to gain access with a drill, then weld the cut off metal back on later?

It's a question of how desperate you are I suppose?

Cant do that, the metal surrounding is actually aluminum and part of the steering column.

[1083 Feedbacks]

steveo3002 said:

yeah any scope to cut holes or cut it in 2 then re weld /repair afterwards

No power tools or weldings can get down this gap. It is too hard to reach.

The best solution i can think of is using some epoxy or JB weld to attach a bolt to it then onto the rounded off torx. Never done anything like that before, so not sure if it would work or not.

[PositronicRay]

1083 Feedbacks said:

steveo3002 said:

yeah any scope to cut holes or cut it in 2 then re weld /repair afterwards

No power tools or weldings can get down this gap. It is too hard to reach.

The best solution i can think of is using some epoxy or JB weld to attach a bolt to it then onto the rounded off torx. Never done anything like that before, so not sure if it would work or not.

I.M.E. (unless it's loose) You'll be on a loser with JB weld, it's strong but not in that (shear) kinda way.

[CoolHands]

You may need to remove the dashboard to get to it?

[DuraAce]

Try posting a picture or two if you want some relevant ideas generating..... But of a tough guessing game otherwise

[finlo]

1083 Feedbacks said:

Cant get a drill in there. Not even a dremel will fit.

With a 90° angled Chuck?

[Mr2Mike]

1083 Feedbacks said:

Cant get a drill in there. Not even a dremel will fit.

A picture would be helpful. What is preventing the use of a drill, is there another part of the column that's getting in the way?

Beating a slightly larger bit into the rounded torx head can work, even a flat screwdriver bit can work if it's the right size.

[steveo3002]

cant see jb weld and the like being any use at all

so what shape tool did you fit in there to round it off?

[1083 Feedbacks]

steveo3002 said:

cant see jb weld and the like being any use at all

so what shape tool did you fit in there to round it off?

The same size T27. Due to the small gap its gone in at a slight angle, that and also the fact im doing it without even seeing what i am doing i managed to sheer it round. But, i did get the other 2 bolts off OK.

TVR Moneypit said:

OK. Another desperate solution here.

Can you drop the column down from underneath the vehicle?

From the joint under the car?. I could but i don't see that giving much more room?. I have the column currently dropped from the intermediate shaft above the pedals. The steering wheel is resting on the seat. I guess i could go through the hassle of taking out the entire column/steering wheel. But im no mechanic, once its out i can drill out that sheered bolt i guess. I really don't want to mess with the clock spring and that.

[1083 Feedbacks]

finlo said:

1083 Feedbacks said:

Cant get a drill in there. Not even a dremel will fit.

With a 90° angled Chuck?

That may work, depends on the size of the chuck. Prices seem quite high mind...

[1083 Feedbacks]

DuraAce said:

Try posting a picture or two if you want some relevant ideas generating..... But of a tough guessing game otherwise

Will do that tomorrow.

[Efbe]

what did you do with the abro steel? did you try putting a large nut on it,