Chewed allen bolt

[alfie698]

Hi all

I was about to take out the forks on my Honda NTV650 for a rebuild, when I found that the allen key bolt holding the stanchion in the top yoke has been chewed up by some muppet. (Probably the same one that stuffed tissues under the fork dust seal to hide the fact that they were leaking. )

Because the bolt is recessed into the top yoke I cant just drill the head off and molegrip the b'stard out. My only thoughts so far are to attack it with a chisel to turn it into a star head to get it out.

Anyone got any better ideas, or are there special tools available for this job?

Cheers, Alfie
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[alains]

if the bolt is big enough (start at diameter 6) you can drill a smaller hole and use a conical extractor (it has a left taping) screwing it inside will undo your bolt .
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[alfie698]

Thanks - off to eBay to see what I can find....
____________________
Ted: "These are small; the ones out there are far away."
Dougal: "I still dont get it, Ted."
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[Kickstart]

Hi

Get a torx bit of about the correct size and hammer that into the chewed up allen key head. Will wreck the torx bit but can often work.

All the best

Keith
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[alfie698]

I already tried that, and unfortunately it was already too chewed up.
One size was a good enough fit to hammer in, but just spun, the next size was way too big, and wouldnt hammer in.

Still the good news is I found an extractor set on eBay for £4 inc p&p. We can only hope that the muppet that owned the bike before me hasnt messed up any other bolts...

Cheers, Alfie
____________________
Ted: "These are small; the ones out there are far away."
Dougal: "I still dont get it, Ted."
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[numbnut]

Is there any gap around the edge of the allen bolt? If so snap on do some external extracters for rounded off bolts. I use these at work when i have rounded off and chewed up allen or torx bolts.

Be carefull when using those extracters off ebay as I have had some snap. If it is fully in and tight you will need a carbide drill to remove it and it will take a lot of time.

[Bezzer]

I'm with Numbnuts , if it is stuck enough to have rounded off you stand a good chance of snapping off those shitty stud extractors, I've only ever used them successfully on bleed nipples.
I'd go for drilling it out, the advantage of allen heads is you already have the centre marked for you so just drill it in increments to just under the actual thread size and you should be able to pick out the thread then or cut it out with a tap.
And just another thought, it isn't a blind hole is it, it goes straight though to the other side?? how about drilling a hole in the bolt that end and trying the Torx bit from that side, you could drill the hole to the right size to take the Torx.
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[thuganomics16]

if all else fails you could try taking a hacksaw to the top of the allen bolt to make a groove in the top and then take it off with a screw driver. My neighbour showed me this trick today and it worked a treat

[thuganomics16]

if all else fails you could try taking a hacksaw to the top of the allen bolt to make a groove in the top and then take it off with a screw driver. My neighbour showed me this trick today and it worked a treat

[alfie698]

Thanks for the tips

Unfortunately the head of the bolt is recessed into the top yoke, so I cant get at head of the bolt. My first thought would have been to use a hacksaw to make a flathead slot, but I cant.

I'm not sure if the hole goes right through, I suspect being an older non-sports bike, the yoke is solid and its a blind hole that its in.

I'll take it easy with the cheapo extractors though, it shouldnt be torqued up too tight, but given that its chewed, god knows how tight it is. Otherwise its drill time, and I've played that game before

Cheers, Alfie
____________________
Ted: "These are small; the ones out there are far away."
Dougal: "I still dont get it, Ted."
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[stinkwheel]

If you have the equipment, build up a load of weld on top of the head of it, then cut your slot in the weld. The immense heat of the welding should make it nice and loose too.
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