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Help on removing worn out allen key bolts?

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  • torker
    replied
    Guys, if they are the ones I'm thinking of, they are for hockey skates and the allen heads could be sunk into the plastic cover (guard). Could very likely be metric. Some of the worst quality fastners I've used are cheap ass metric crap. Even when heated they will still bust off. I have a whole Toyota full of broken bolts (sigh).
    Russ

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  • wierdscience
    replied
    A flat washer that fits the head od tight for protection and a MIG welder work wonders.

    Just build up a stud of weld on it and vise-grip out.

    They do make easy-outs for socket head screws called Soc'em outs,but I have never used them.

    You can also use a drill bit the same size as the original allen wrench and drill the head off the screw.Then remove the part the screw holds on and vise grip out the remainder.

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  • jimfun
    replied
    5 flute low helix easy out. There is nothing better.

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  • C. Tate
    replied
    What type of head and can you get to it? If you are dealing with counterbored hole and nothing else works try drilling from opposite side. If you cannot get in from that direction try left handed drill from the top. Drill will hpoefully hang and spin out screw. If not drill it out and retap. Drill straight !!!!!! Use cheap drills and buy more than one.

    CT

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  • spope14
    replied
    I have a method I kind of learned from this board. i take a sharpened small chisel, and "burr" the old flats back into the hex area. Then I tap in the hex wrench and turn them out. Sometimes ou have to burr it in with the hex key already in, but it works. The original idea was to take a rounded center punch or line punch and tap the hex to burr it in, then put in the hex key.

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  • Guest's Avatar
    Guest replied
    If all else fails you can weld a nut on it and let cool, then spin it off.

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  • Yankee1
    replied
    I have used vise grip pliers with good results.

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  • Lynn Standish
    replied
    Use one of the methods above, in combination with epoxy between head and removal tool. Let it set up and remove the bolt.

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  • Steve Steven
    replied
    You can take a #409 thin cutter disc on a Dremel tool and cut a slot across it and use a straight blade screwdriver on it.
    Steve

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  • coles-webb
    replied
    Depending on how badly it is worn, a metric hex key can be tapped in and will not slip. As with any stuck bolt or screw, I always use release agent or thin oil on the screw first(AeroKroil works the best I find). You can also drill a small hole through the screw and spray oil through it so it can soak from the back side also. The small hole will sometimes release pressure on the screw and ease it's removal. Good luck.

    Mike

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  • G.A. Ewen
    replied
    Any of the above should work. Adding a cheap impact driver into the mix will ensure success.

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  • torker
    replied
    I've had good luck hammering in a hardened Torx bit. this sets the bit and as suggested will shock the allen bolt.
    Russ

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  • ERBenoit
    replied
    You could also use a socket screw extractor. That is exactly what they are made for.

    [This message has been edited by ERBenoit (edited 03-29-2005).]

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  • Guest's Avatar
    Guest replied
    A spiral stud remover will work.

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  • speedy
    replied
    Impact the Allen head with a punch to shock loosen the thread then you could try hammering one of those star drive bits in; if that fails try the slow method with a cold chisel or centre punch.

    I hope this is of some help.

    cheers, Ken

    PS .Get a set of good quality Allen keys, use them correctly and junk the others.

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