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Unread 2012-04-06, 08:09 PM   #1
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Default Removing a stripped bolt

A customer had 9 Torx bolts strip out on him tonight. After some internet research, he found an interesting way to resolve the situation. By using a cutting wheel, he cut a slot for a screw driver bit in the bolt. He then used a 1/2" drive ratchet, was able to remove the bolts.

I just thought this was a great idea and thought I would share it. I haven't had much luck with bolt extractors and such.

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Unread 2012-04-06, 08:10 PM   #2
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Works with larger fasteners and an air hammer too if you have access.
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Unread 2012-04-07, 11:20 PM   #3
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i was going to say air hammer works great also
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Unread 2012-04-08, 12:54 AM   #4
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Been using that method with a Dremel for years. Put a notch in it and use a flathead impact driver.
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Unread 2012-04-10, 02:15 PM   #5
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I just pound a triple square into it and turn it out
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Unread 2012-04-10, 02:18 PM   #6
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I just pound a triple square into it and turn it out
Not everyone has those silly things.

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Unread 2012-05-16, 10:09 AM   #7
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I've used this method before, works great if you have room to get a grinder/cutting wheel to the bolt.
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Unread 2012-05-16, 08:40 PM   #8
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I have used the dremel method a few times. Another last resort is one I used this weekend on a broke header bolt. Get out an old socket and slip it over whats viewable of the bolt. Weld it to the bolt and crank it out. ( also if the bolt wont take try welding either side of the,bolt . It creates an uneven surface allowing vice grips to grab)
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Unread 2012-05-20, 04:51 PM   #9
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Air hammer for the win!!!!

Thought most techs knew this stuff? All them pesky honda rotors held on by Phillips bits!!!

I always found it best to use a hand held impact driver, or smack around the head with a flat round chisel + hammer to free it up.


Also if you got a screw that is hella stuck, push down as hard as you can with the screw driver, put a little bit of twisting force "not near enough to strip / turn it" then start smacking the screwdriver with a hammer, works wonders.

They also make a 3/8th and 1/2 drive attachment for air hammers that lets you do this!
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Unread 2012-07-29, 07:56 PM   #10
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O you can use an oversized nut & washer, place them over the bolt and mig weld them to the top. The washer is handy when things break off flush as it helps preventing you from welding anything other than to the bolt. Also the heat from welding will help with removal.
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Unread 2012-10-23, 08:17 AM   #11
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If you ever get one busted off flush, take the blow torch to it (protect face). The bolt will blow out long before an iron head/block will get too hot. Wont work in alloy, but you seldom break a bolt off in an alloy engine.
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