Rounded hex and Allen bolts

[Steve-O]

Check this out. Was changing the plugs on the S3 this morning and sods law the very last bolt that holds a bracket that obscures the last 2 plugs was chewed up. Not happy. 

 

Cue 3 hours cursing and having to buy some expensive metal bits and easy outs. The little s**t finally budged:

 

 

 

I was quite pleased i got it out. Replaced them with hex though.

 

 

Question is : who knows of any genius bolt removal tools for rounded bolts that is less hassle than easy outs? Or any tricks even?

 

Cheers

 

Steve

[NickT]

Could you use a stud remover on it?

I've found that the one that looks like a drill chuck work ok.

[adam_r]

Steve.. I normally get a cheap screw driver set ( nice soft metal) and hammer it in to the centre, then twist....

 

or the other option is to use a Tx tool ( star shape ) they normally work very well

[Steve-O]

In this situation there was no room around the bolt as it was sat in a recess in the head. I tried tapping on a socket but the metal was too hard and I thought about the screwdriver but I just couldn't get enough leverage. It was properly welded tight. When I got it, it snapped loose.

 

A torx socket tapped in might have worked but given the socket didn't make much of an impact I had to admit defeat and do it the hard way to ensure I finished the job.

 

There must be some kind of hardened socket set out there with threads that you can tap on and then use a socket to bite into the metal and release it? Just small versions on locking wheel nut removal sockets perhaps?

[Tony]

I don't think there's any specialist tools so it's down to ingenuity and knowledge i'm afraid..... In the past we have welded a nut onto the offender but as you say in this case room was an issue.