Removing rounded allen head bolts?

[Toaster Pilot]

The two bolts at the front of the driver's seat of my shed have been ruined by someone trying to remove them in the past, they're completely rounded out to the point where I can't use any size allen key in them.

What's the quickest, easiest way to get them out? Bearing in mind space is quite limited too thanks to the location.

[littleredrooster]

Could you hammer a slightly-larger Torx bit into them? Access permitting, this has worked for me almost every time.

[Crusoe]

cut a small groove and then use a normal screwdriver. A Dremel or similar is good for that kind of thing. Or you could try going up slightly in allen key size and see if it would hammer in.

[Toaster Pilot]

I tried hammering in a bigger allen key and it just rounded further despite soaking it in WD40 and giving it a good old clout with the hammer.

[mikes2w]

Irwin twist sockets are good for getting rounded bolts out

http://www.machinemart.co.uk/shop/product/details/...

[Toaster Pilot]

mikes2w said:

Irwin twist sockets are good for getting rounded bolts out

http://www.machinemart.co.uk/shop/product/details/...

I was going to buy these in the motor factors the other day to do this job however I thought that because they're not hex bolts and instead are round with the allen slot in the middle it wouldn't get a good enough grip of them - am I wrong?

[Huff]

I had a similar problem in a very difficult to access area on my Fury . In the end I drememeled the (stripped, button-) heads off, released the part retained and then was able to get molegrips on the remains protruding to wind-out the threaded stubs. NB it does require that the part being held has some thickness, so you have say 10mm of threaded stub to attack later.

Worst case - grind off head, remove seat, drill-out remains and re-tap for new bolt

[mikes2w]

They'll grip a round bolt no problem. Used them several times for this exact reason

[kev b]

Use a sharp centre punch on each flat of the allen bolt, this should tighten it up enough to get the key to grip, unless it is majorly borked.

I have used this method many times with success, you may have to strike each flat three or four times to squash it in enough.

[CrutyRammers]

mikes2w said:

Irwin twist sockets are good for getting rounded bolts out

http://www.machinemart.co.uk/shop/product/details/...

They look like quite a clever idea

[Toaster Pilot]

mikes2w said:

They'll grip a round bolt no problem. Used them several times for this exact reason

Looks like I'm buying a set of them then! I'm sure they'll come in handy with all of the other rusty rounded knackered ste that holds this car together!

[littleredrooster]

Toaster Pilot said:

I tried hammering in a bigger allen key and it just rounded further despite soaking it in WD40 and giving it a good old clout with the hammer.

Which is why I suggested a Torx bit...a Torx bit, not a Torx key; hammer it in nice and square to the full depth of the recess and it should shift it unless it's made of cheese.

WD40 as a penetrating oil is as much use as a one-legged man in an arse-kicking contest. Get some PlusGas, some heat and some violence.

[Toaster Pilot]

Could you suggest a reasonable quality but not ridiculously expensive set of Torx bits?

Not sure how I could get heat in there without setting fire to the world given the location but violence I'm up for

[Krikkit]

littleredrooster said:

Toaster Pilot said:

I tried hammering in a bigger allen key and it just rounded further despite soaking it in WD40 and giving it a good old clout with the hammer.

Which is why I suggested a Torx bit...a Torx bit, not a Torx key; hammer it in nice and square to the full depth of the recess and it should shift it unless it's made of cheese.

WD40 as a penetrating oil is as much use as a one-legged man in an arse-kicking contest. Get some PlusGas, some heat and some violence.

Agreed on all counts. I have a set of these and they work wonders on a damaged socket-cap head. At that price you can afford to be a bit brutal with them too.

[littleredrooster]

My learned friend has beaten me to a recommendation; Halfrauds, I believe, sell individual 3/8" or 1/2" -drive Torx bits if you wanted to just buy one rather than a set.

[eltax91]

Toaster Pilot said:

Could you suggest a reasonable quality but not ridiculously expensive set of Torx bits?

Not sure how I could get heat in there without setting fire to the world given the location but violence I'm up for

Halfords Pro. Hammer the fk out of them, and if they break, you get a freeby as they have a lifetime warranty

[WinstonWolf]

kev b said:

Use a sharp centre punch on each flat of the allen bolt, this should tighten it up enough to get the key to grip, unless it is majorly borked.

I have used this method many times with success, you may have to strike each flat three or four times to squash it in enough.

You can use a centre punch to create a dimple then drive the fastener undone using the dimple. It acts like an impact driver

[anonymous-user]

You would be able to use a bolt/screw extractor bit if you had the right size drill bit (for metal).

[magooagain]

Footprint plumbers grips. For sale everwhere.

[mrloudly]

Top tip if they're in good condition, tighten before loosening, no idea how it works but it does ;-)