Getting a rounded bolt out

[s44678]

Rounded off a bloody axle clamp bolt didn't I...

So anyway would this technique work for getting it out?:

It's an allen key type, with a like a tapered cap head on the bolt, so I was thinking I could use a hacksaw to cut a groove across the bolt then use a flat-head screwdriver to get it out?

Or any other ideas?

[Tristan.]

Lol, kawasaki.

That should work fine, alternatively (this only tends to work on larger ones mind) you could hammer in a 1 size up allen key or an imperial one if you can find one.

heat on the fork bottom and penetrating fluid always help

[s44678]

Yeah yeah! I'm a cock I know.... Had to start with bike DIY somewhere didn't I! Just happened to be on my actual bike rather than a project!

So get some WD40 in there first? How much heat on the fork leg? (don't want to cock it up even more)

[Mudskipper]

[s44678]

Is that not best for slightly bigger bolts though? Where you have a bit more bolt 'meat' to whack the oversize torx bit into? Don't want to strip it again and leave nothing there.

[yen_powell]

Cut a slot then use an impact driver with a slotted bit so you get it out in one go.
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XT1200Z and a DR350 in bits

[BanditsHigh]

As mentioned above a torx bit is best ... it'll be easier to hammer in as you have less metal to 'shift' out of the way (six points) unlike a hex bit (six flats) and it'll grip just fine.

The hacksaw/screwdriver would also work but give you less metal to lever against compared to the torx.

As a last resort, weld another bolt onto it and use that to undo it.

Hope you get it sorted