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The wonders of rusted rounded off screws

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Willson
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Joined: 26 Jun 2010
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PostPosted: 08:46 - 24 Jul 2010    Post subject: The wonders of rusted rounded off screws Reply with quote
Hey dudes,

Just bought new throttle cables for my Kawasaki ER-5, and to my utter dismay one of the screws that holds the switchgear on is rusted and rounded off at the top.

Any ideas how I could set about removing it without damaging the handlebars or switchgear itself?

Thanks!

Willson
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Riding: '00 Suzuki SV650S. Previous: '99 Kawasaki ER5 - sold, '02 Suzuki GZ125 Marauder - sold
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Carl_steveo
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Joined: 23 Jun 2008
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PostPosted: 09:22 - 24 Jul 2010    Post subject: Reply with quote
Have you got a dremmel???? If the answer is yes, cut a groove in the bolt and use a screwdriver to turn it out.

If the answer is no can you weld??? If the answer is yes, tac a upside down bolt on top of it and turn it off using a spanner.

If the answer is no then I have run out of suggestions lol. Thumbs Up
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ms51ves3
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Joined: 07 Jun 2007
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PostPosted: 09:29 - 24 Jul 2010    Post subject: Reply with quote
Carl_steveo wrote:
If the answer is no can you weld??? If the answer is yes, tac a upside down bolt on top of it and turn it off using a spanner.


Great for melting the plastic switch gear.

If you can't cut a slot in it, you need to remove the screw head, then split the switch gear and use pliers to remove the stub.
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neil.
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Joined: 24 Feb 2008
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PostPosted: 09:37 - 24 Jul 2010    Post subject: Reply with quote
https://www.fordprobestore.co.uk/store/images/plusgas1.jpg

+ a few hours +

https://g-ecx.images-amazon.com/images/G/02/ciu/a2/39/7672017b42a0f3ae035b1210.L._SL500_AA300_.jpg
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Willson
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Joined: 26 Jun 2010
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PostPosted: 09:40 - 24 Jul 2010    Post subject: Reply with quote
Cheers for the suggestions guys,

Now off to my Dad's to try and find said tools!

I wouldn't mind, but I've got a spare lot of switchgear... but the same problem. One feckered screw.

It never rains it pours eh?
____________________
Benson: Wouldn't life be easier if we were all turtles?
Me: Pig on bread = The way forward.
Riding: '00 Suzuki SV650S. Previous: '99 Kawasaki ER5 - sold, '02 Suzuki GZ125 Marauder - sold
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stonesie
World Chat Champion



Joined: 04 Jul 2010
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PostPosted: 10:17 - 24 Jul 2010    Post subject: Reply with quote
You have a spare screw then?

Battery drill on slow
Sharp suitably sized drill bit
Patience and care

Combine that lot and you can drill the head off it without causing damage then tackle the remains with molegrips Thumbs Up

Just take it slow, you want to keep the temperature down to avoid melting the plastic.
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Skinned
Renault 5 Driver



Joined: 17 May 2010
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PostPosted: 14:28 - 24 Jul 2010    Post subject: Reply with quote
Depending on the extent of the rounding on the screw you can tap in a suitable size torx head bit into it and turn it out that way. I've done this on a few rounded screws and works well, wortha try before you start drilling away.
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Vincent This post is not being displayed because the poster is banned. Unhide this post / all posts.

Carl_steveo
World Chat Champion



Joined: 23 Jun 2008
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PostPosted: 16:37 - 24 Jul 2010    Post subject: Reply with quote
ms51ves3 wrote:

Great for melting the plastic switch gear.



Only if your heavy handed and fucking blind. Laughing
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Skinned
Renault 5 Driver



Joined: 17 May 2010
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PostPosted: 17:49 - 24 Jul 2010    Post subject: Reply with quote
Vincent wrote:


That technique only realy works for allen screws, not much use for philips screws.


As long as you got a good range of torx heads it can be used on quite a few different phiilips heads, usually on the brake reservoir when they seize. Just tap the a suitbale torx head in with a hammer and ratchet off.
It worked particularly well on the old Ford Capri I stripped as every single screw on it was rusted to hell, much like the rest of the car.
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Old Thread Alert!

The last post was made 15 years, 192 days ago. Instead of replying here, would creating a new thread be more useful?
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