Removing a nearly rounded allen bolt [Archive]

breakaway

22nd July 2008, 16:49

Trying to remove fairing from my GSXR 600 today, and after removing all the bolts, I discovered that the last one was rounded! Looks like the prick that had it before me did it.

It is a 5mm bolt, one like this:

<img src='http://www.blueridgeperformance.net/images/silverscrew.jpg'/>

I don't think I am going to be able to get it out using any conventional means. It's so badly rounded that the allen key has absolutely no grip, it just turns.

How do I get it out? :crazy:

scumdog

22nd July 2008, 16:55

Could you tack-weld another bolt to it without burning anything??

Maha

22nd July 2008, 16:57

You may have to hacksaw across it and use a flat head screwdriver.

Gubb

22nd July 2008, 16:57

Get a Phillips screwdriver slightly bigger then the hole, put it over the bolt, smack it with a Hammer and turn.

Maha

22nd July 2008, 17:00

Get a Phillips screwdriver slightly bigger then the hole, put it over the bolt, smack it with a Hammer and turn.

Yeah....and I know a good plastic welder up here for your pending cracked fairing....:Oops:

vifferman

22nd July 2008, 17:02

How tight is it? I'd try wedging summat in there, like an allen key and some tinfoil. Other options:
- Hammer an old screwdriver into the head.
- Use some strong epoxy such as JB Weld to glue an old allen key or somesuch in there.
- Drill a hole in it and use an Ezy-Out.
- Use a Dremel to cut a slot in the head, and use a slotted screwdriver.
- Grind the head off, then dribble WD40 or penetrating oil into the threads. Leave for a while and use locking pliers on the stub to turn it.

breakaway

22nd July 2008, 17:10

Could you tack-weld another bolt to it without burning anything??

Don't have the skills or the tools for that :pinch: and I'm sure I'd melt some fairing in the process even if I did

Get a Phillips screwdriver slightly bigger then the hole, put it over the bolt, smack it with a Hammer and turn.

Didn't have any idea it was that simple, will give it a try later and post back.

You may have to hacksaw across it and use a flat head screwdriver.

Might be time to buy a hacksaw! Can I just use screwdriver + hammer or would it be better to buy a hacksaw? With a limited amount of funds I'd really like to take the cheapest option out but don't want to fuck it up even more in the process.

Gubb

22nd July 2008, 17:18

As Maha said, be very careful about your fairing, last thing you need is a crack.....

breakaway

22nd July 2008, 17:20

How much for a decent hacksaw then? Don't want an asian brand. I'd like to purchase a good one that will actually last.

P38

22nd July 2008, 17:24

Pein the head around the hexagonal socket with a light ball pein hammer untill a new Allen Key wont fit.

Squirt some crc around it too

This will tighten the socket and loosen the bolt.

Tap the new allen key into the tightened socket and gently loosen the bolt.

Might have to do this a couple of times.

Becareful not to crack the faring.

Good Luck

Spazm

22nd July 2008, 17:31

You could try an easy-out stud extractor if you have no joy with deforming it with a hammer

westie

22nd July 2008, 18:26

Dude give me a call

FLYMO

22nd July 2008, 19:12

hey being a metric bolt why not try a imperial allen key
they some times are a tighter fit
either that or get one of those torq fittings(star shaped) and wedge that in there
more bits biting in the better

Zealot

22nd July 2008, 19:21

Try an impact driver? Although I'm guessing you don't have one...
If you do, whack something solid behind it, and beat the end of it with a hammer. Having a solid object (ie an anvil of sorts) behind it will stop it bouncing around and cracking the fairing.

Also try spraying with CRC a number of times.

Failing that, a drill always works.

rok-the-boat

22nd July 2008, 19:28

Or, if it's clean, put the allen key in with a bit of that epoxy putty stuff, let it hardem, then turn it. Might be best to do it with a smaller size allen key to get more putty in. Never tried it - just thought of it.

Me though, I'd hit it at an angle with a small cold chisel to get it turning. Once you crack it free, it'll probably just unscrew with your fingers.

rottiguy

22nd July 2008, 19:29

If the other end of the bolt is accessible you could grab it with vicegrips and turn it. Or try a flatblade screw driver and tap it into the widest bit and try turning. Or maybe superglue the allen key in and try turning once it has set.
That's my best guess without seeing it first hand. Good luck

Trying to remove fairing from my GSXR 600 today, and after removing all the bolts, I discovered that the last one was rounded! Looks like the prick that had it before me did it.

It is a 5mm bolt, one like this:

I don't think I am going to be able to get it out using any conventional means. It's so badly rounded that the allen key has absolutely no grip, it just turns.

How do I get it out? :crazy:

manicmedic

22nd July 2008, 19:58

No-one so far has surgested taking the bike to a dealer / workshop. Most I have found to be happy to lossen a bolt for a beer. If your g/friend can take it in ..... all the better.

Manic

westie

22nd July 2008, 20:14

Bah slide it down the road.. It'll be off in a jiffy

Max Preload

22nd July 2008, 20:54

How much for a decent hacksaw then? Don't want an asian brand. I'd like to purchase a good one that will actually last.

Just get a hacksaw BLADE. You'll only end up taking the frame off anyway because it'll get in the way. Pinch the blade between your thumb and first 2 fingers and gently drag it across the head to get it started.

Failing that, drill the head off using a drill the same diameter as the thread.

Cruisin' Craig

22nd July 2008, 21:10

You could try an easy-out stud extractor if you have no joy with deforming it with a hammer

I second that. They've worked for me so far :-)

birdhandler

23rd July 2008, 17:44

here you go Easyouts from jaycar 12 bucks last you a lifetime

http://www.jaycar.co.nz/productView.asp?ID=TD2079&CATID=&keywords=screw+extractor&SPECIAL=&form=KEYWORD&ProdCodeOnly=&Keyword1=&Keyword2=&pageNumber=&priceMin=&priceMax=&SUBCATID=

5 Piece Screw Extractor Set

Also known by the trade name of 'Easyouts', these are the only real way to get a completely stripped or mangled screw, bolt or stud out, even if the head has broken off completely. You simply drill a hole in what remains of the offending fastener, then use the appropriate size screw extractor with a tap wrench. They have an aggressive left-handed thread that bites into the metal, enabling you to unscrew the damaged fastener. This is the kind of tool you need once in a blue moon, but when you need them, they're indispensable.

• Sizes: 1/8", 5/32", 3/16", 1/4", 5/16"
• Case size: 120(W) x 120(H) x 15(D)mm

P38

24th July 2008, 17:12

oldrider

24th July 2008, 17:24

drill the head off using a drill the same diameter as the thread.

As Max Preload said, drill the head off remove the faring then fix the errant bolt when you can get at it more easily.

You may need to replace some of the faring screws you have taken out, to support the faring while you drill the offending screw head off.

If you don't know how to drill it out, find a friend who does. Good luck. John.

scumdog

24th July 2008, 20:24

Be aware that SOME of those things are almost too hard to be marked with a hack-saw or file.:(

Titanium

24th July 2008, 20:47

Get a torx bit one size up from the hex head and drive it in to the rounded out hole, will come out easy peasy. More points of contact. Use a socket to undo it.

The torx is tapered so easy to drive in and make tight.

Worked many times in the past.

To easy!

westie

24th July 2008, 22:53

Don't have the skills or the tools for that :pinch: and I'm sure I'd melt some fairing in the process even if I did
Didn't have any idea it was that simple, will give it a try later and post back.
Might be time to buy a hacksaw! Can I just use screwdriver + hammer or would it be better to buy a hacksaw? With a limited amount of funds I'd really like to take the cheapest option out but don't want to fuck it up even more in the process.

Sooooo?? Did ya get it out or are you waiting to see how many different ways we can come up with?

breakaway

25th July 2008, 11:08

westie

25th July 2008, 18:12

Not yet, been busy with uni etc. (first week back) Matters are complicated by the fact that I don't have a drill etc, and I'm working heaps as well.

I'll probably get in touch with you sometime next week westie!

Edit: I did try metric keys, didn't have any luck though. It's well and truly fucked.

Dude I went round morcs the other day and he was crying bout an allen bolt that wasnt ever coming undone, ever!
Had it un done in the time it took him to go get the tissues. We having biker shed beers night tonight come round if ya keen.(main focus on the beers tho) But could take your bolt off and replace it with another if ya want.

Pedrostt500

25th July 2008, 18:49

Ah just get the ARK Air GOUGING on to it , thats the Heavey engineering approach.

Ixion

25th July 2008, 19:00

Cemtex. Never fails.

westie

26th July 2008, 00:50

Cemtex. Never fails.

If you have a mould you can shape it like a barbie and ........(give it to the children)

Wired1

26th July 2008, 18:56

I've never had much luck with easy-outs they always seem to break on me. I've used the dremmel with a grinding/cutting disk on the end but this needs a bit of room either side otherwise you'll cut the fariring. If the allen hole is buggered it's probably because the bolt is seized into whatever it's screwed into so you're probably going to have to drill the head off and hope that a quarter of an inch is left when you take the fairing off - which you can then get the vice grips onto. If you snap this off then you'll have to drill out the bolt and re-tap it for a new one, just remember to drill the exact centre and keep the hole smaller than the original bolt size otherwise it goes from a minor inconvenience to a major problem. But remember - it's only a fuckup if it can't be fixed!

wysper

29th July 2008, 16:41

Yeah I would like to know too.. and what method worked .. or didnt:bash:

cmon - you can tell us..

ManDownUnder

29th July 2008, 16:55

You may have to hacksaw across it and use a flat head screwdriver.

What he said but use an impact driver. 2 hacksaw blades side by side in the saw to make a wide(ish) slot, then impact driver it out. Another good option is a strauight bladed scrwdriver bit in a battery drill with the impact/hammer action lightly on.

Hammer away at it to loosen it. Start on a low setting, getting progressivley higher if you need to.

oldrider

29th July 2008, 21:42

I deleted my post about this becoming just another inconclusive thread because when I read it, I thought it a bit over the top and inappropriately worded.

I do however stand by the assertion that too many threads on KB (like this one) do just become inconclusive and taking up valuable space on the site.

Will this just be another one? or will you finally tell us what happened? :shifty: John.

Wired1

29th July 2008, 21:52

I, for one, preferred your first comment. Fuck the PC brigade.

boomer

29th July 2008, 21:52

homer

29th July 2008, 21:53

try using an imperial allen key , might just hold enough to loosen it

erik

30th July 2008, 08:04

I deleted my post about this becoming just another inconclusive thread because when I read it, I thought it a bit over the top and inappropriately worded.
Haha :)
I thought your post was a bit harsh, but agree it would be good to hear how things turned out.

southernmike

30th July 2008, 08:49

I'm guessing that it is rounded off because the bolt is seized in the thread. The previous owner would have had a better shot at getting it out with the allen key and obviously failed (Can't see them rounding it off when they tightened it up but it does happen)

Guess you will have to drill the head off. Remove the fairing. Extract the rest of the bolt.

vifferman

30th July 2008, 09:13

I'm guessing that it is rounded off because the bolt is seized in the thread. The previous owner would have had a better shot at getting it out with the allen key and obviously failed
... and then sold the bike because he couldn't do whatever it was that he needed the fairing off for.
"Ah crap! Can't get this bolt off. The bike's fukt now, so I'd better get rid of it!".
You know how it is.:doh:
Actually, my last bike had shades of that (posted on here). The sump bolt was completely rounded off, and VERY tight. There was also very poor access to get at it.
In the end, I had no option but to drill a hole in it, and use an Ezy Out. I very tentatively (bearing in mind the likelihood of it snapping, as has happened before) leaned on it with the spanner, then a bit more.... a bit more... CRACK!!
Uh-oh....
That doesn't sound good.... :confused:
Opened my eyes....
The Ezy Out was still alive! :clap:
The sump bolt had given up its maniacal death grip on the sump!
Man, was I relieved. :laugh:

Badjelly

30th July 2008, 09:51

I deleted my post about this becoming just another inconclusive thread because when I read it, I thought it a bit over the top and inappropriately worded.

A bit over the top? Inappropriately worded? I'll say, you fucking time-wasting tosser!

Oops, got a bit carried away there :o.

oldrider

30th July 2008, 10:51

A bit over the top? Inappropriately worded? I'll say, you fucking time-wasting tosser!

Oops, got a bit carried away there :o.

Ha ha, fair enough.

I went for a ride on my bike and it was just magic!

Read my post again when I got home and I thought, "That's probably a bit tough" so I deleted it.

You have every right to call me a time waisting tosser. :yes: Cheers John.

Badjelly

30th July 2008, 11:22

You have every right to call me a time wasting tosser.
And you have every right to call me a sad-faced git whose only remaining interest in life is in dragging everyone else down to his own pathetic level.

But you've got to wonder: has he fixed the bloody bolt yet?

Max Preload

30th July 2008, 12:25

i took mine to my car mechanic who took it out; get a 1 or 2 mil drill piece. Drill into the head near the outside. then get a nail punch, place in newly made indent and tap anticlockwise with a hammer.

That's ok if there's solid support behind it. But where it's merely a screw in a fairing join, damage is easily inflicted with any impact.

I'm guessing that it is rounded off because the bolt is seized in the thread.

I feel it would be more like the scenario whereby it was rounded by a not fully inserted key when the previous butcher... I mean 'installer' overtightened or even more likely went to loosen it.

I think 'breakaway' might be dead. I half jokingly sent him a text to come around on Saturday and we'd remove the bolt, but never heard anything back...

boomer

30th July 2008, 17:48

That's ok if there's solid support behind it. But where it's merely a screw in a fairing join, damage is easily inflicted with any impact.

Well where else do you find fairing bolts..??!!! you tap it..!!!

jeeeez

Max Preload

30th July 2008, 17:54

Well where else do you find fairing bolts..??!!! you tap it..!!!

jeeeez

Ummm frequently between upper and lower sections with no support behind it... just with a panel clip for the thread.

westie

31st July 2008, 21:44

This thread is funny.
Lots of guys incessantly wondering if the fella got his screw or not:buggerd:
:laugh:
Even getting frustrated

Skyryder

1st August 2008, 13:05

Ya need something like this

http://www.axminster.co.uk/product-Axminster-Cobalt-Drill-and-Easy-Out-Set-462398.htm

Skyyrder

Winston001

8th August 2008, 12:30

Well....?? What happened??

kimjie

19th August 2008, 23:16

what the heck is this thread? does the guy got that bolt out yet??? if not just bring that to the nearest shop and let them do that.... (if he's working he should have money for that) goodluck..

:confused:

blue eyed savage

19th August 2008, 23:20

angle grinder. good for removing everthing or find somone with an easy out.

breakaway

9th November 2008, 14:50

Finally got it out :calm:

<img src='http://iforce.co.nz/i/3574c35776be959bc38db1cf88cd2b49.JPG'/>

imne1

9th November 2008, 15:18

you can VERY carefully remove it using a sharp pin punch and a moderate size hammer, tap it in straight first so it has a good grip then angle the punch so that you turn it anti clockwise and Hey Presto !! ... one loose bolt.

Winston001

10th November 2008, 07:54

Good man and thanks for the update.

themechanics

12th November 2008, 20:13

hay p38 had the right idea if that dont work ya can drill the head off it gd lk
bazza

puddy

12th November 2008, 20:32

Finally got it out :calm:

<img src='http://iforce.co.nz/i/3574c35776be959bc38db1cf88cd2b49.JPG'/>
It looks like a tinny jammed in there!:shit: Fucking potheads!:shifty::shifty:

roadracingoldfart

12th November 2008, 20:41

I cant be naffed to read every page to see if this ones been covered.....
If you have a Phillips , Pozi , Inhex (allen key) or anything with a female drive and its a bit rounded and wont grab with the rite tool .
Try this -----
get some Valve paste , Jif , cutting compound, flour mixed with a bit of oil , chalk or any kind of gritty paste and smear it into the damaged drive recess. The gap filling property of the gritty paste will take the clearance up with the tool and the damaged bolt / screw , whatever can most times be removed in a normal fashion.
You can even splash out and buy the real Mcoy from Re-coil (the re-coil insert brand) if you want but a good old gritty shit will do just as well.
Its got me out of the shit a few times and its simple with little cost, and the skill level is classed as retarded level. (thats why i know how to do it).

Paul.

westie

13th November 2008, 13:44

Friggen finally breakaway!
Good piccy of the offending bolt.
In hind sight a tap with a hammer and your fingers could of gotten the thing out.:laugh:

Scouse

13th November 2008, 14:06

Trying to remove fairing from my GSXR 600 today, and after removing all the bolts, I discovered that the last one was rounded! Looks like the prick that had it before me did it.

It is a 5mm bolt, one like this:

I don't think I am going to be able to get it out using any conventional means. It's so badly rounded that the allen key has absolutely no grip, it just turns.

How do I get it out? :crazy:Drill it out and use a screw extractor, its somthing that looks like a tap but instead of a thread on it it has an anti clockwise helix. Just be carefull not to use to big a drill, otherwise the screw extractor may cause the bolt to expand, if that happens your basicly fooked.

westie

13th November 2008, 14:12

Drill it out and use a screw extractor, its somthing that looks like a tap but instead of a thread on it it has an anti clockwise helix. Just be carefull not to use to big a drill, otherwise the screw extractor may cause the bolt to expand, if that happens your basicly fooked.

Check out the picture above

Scouse

13th November 2008, 14:16

Check out the picture aboveCool good one westie it suprises me the amount of butchers out there with some of the advise he was getting.Bling for not being a butcher

westie

13th November 2008, 22:07

Cool good one westie it suprises me the amount of butchers out there with some of the advise he was getting.Bling for not being a butcher

Lol I can be a butcher(just ask morcs about his fairings)
I obviousely hadnt had many beers when we did breakaways bolt.

Moki

19th November 2008, 22:08

Try a screw extractor?

shafty

19th November 2008, 22:39

Settle Down Guys - the Dude got the bolt free about 8 posts ago and still the "Tim the Tool Man" macho advice is gushing forth, FFS!

Don't you have a nice Manufacturers 0800 help me card in your wallet?

Sheeesh, You can dial without putting your drink down.

OR buy a Honda!

Merry Christmas! Only 30 something sleeps, - or 3 if you're baking "P".