Looking for tutorial on removing a stripped hex-head bolt - Stromtrooper Forum : Suzuki V-Strom Motorcycle Forums
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post #1 of 17 Old 04-19-2017, 02:12 PM Thread Starter
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Looking for tutorial on removing a stripped hex-head bolt

When I purchased my 2012 Wee a few weeks ago, the seller pointed out one bodywork bolt that was stripped out. He had a drill-bit-type bolt extractor kit and replacement bolt in-hand, but hadn't gotten around to making the swap. Upon purchase, he gave me both the replacement bolt and the extractor kit.

I don't have much experience with bolt extractors, but figured it can't be that hard. Until I tried to do the job the other night. All that happens is the extractor bit spins in the bolt head. Obviously, I'm doing something wrong. So I turned to my online tutor, Mr. YouTube.

Unfortunately, I can only find videos that show how to remove a sheared off bolt; none for a stripped, but otherwise intact, bolt.

Anyone have any suggestions?
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post #2 of 17 Old 04-19-2017, 02:40 PM
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Is it (or was it) a mushroom style hex head?
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post #3 of 17 Old 04-19-2017, 02:40 PM
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Looking for tutorial on removing a stripped hex-head bolt

A picture of the stripped bolt might help determine your best option.
If there is enough bolt head sticking out, grab it tightly with vice grips.
Sometimes if you have room you can cut a groove in the head with a hacksaw or dremel tool then remove the bolt with a slotted screwdriver.
If you trying to use an ez-out type extractor, be sure the hole you drill is the correct size and it MUST be drilled in the center of the bolt. You can tap the extractor into the hole as you're turning it counterclockwise. Tapping it will help it grab and stop slipping.


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post #4 of 17 Old 04-19-2017, 04:06 PM
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The method is going to depend on several factors.

If it is a socket type screw you can drill the hex hole to the same diameter of the threaded bolt. As soon as the head is drill to its base the head will come off. This is good if you can get a pair of vise grip on the remaining part of the screw and spin it out. Or use a thin blade cut off tool to put a slot in the head for a screw driver.

A left handed drill bit works really well as it will oten spin the screw out while drilling it. See harbor freight tools.

But lets see the pic.

http://www.harborfreight.com/left-ha...-pc-61686.html

Last edited by richlandrick; 04-19-2017 at 04:09 PM.
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post #5 of 17 Old 04-19-2017, 04:37 PM
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Best bet is to find a way to get some vise grips on the head of the bolt. If the vise grips are just chewing it up you can try and shape the head with a dremel or grinder to get a flat side or two for the vise grips to grab on to. For a hex bolt this is not so bad, I've never done it on a mushroom cap, seems like that would be difficult.

Never had much luck with extractors myself, especially with bound up bolts. If all else fails I would just drill the whole thing out.
Best case your steady hand manages not to take much of the internal thread, you may have to pick some of the left over bolt material. Worst case you drill the hole out a little bigger, thread it a size up and put a new bolt in (unfortunate downside is you have an odd man out non conforming bolt)
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post #6 of 17 Old 04-19-2017, 04:40 PM
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Quote:
Originally Posted by mongooseknight View Post
thread it a size up
meant to say "tap" it a size up
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post #7 of 17 Old 04-19-2017, 07:33 PM
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If one of the mushroom heads, saw a slot across it for a big screwdriver. An impact driver might be needed. I think I had an EZ Out (bolt extractor) work once in 30 years. I've had some break off in the hole, more just ream the hole out, and I quit using them long ago.

For next time, take a look at your hex bits (Allen wrenches). If any of the ends are rounded, even a little, either toss and replace them or grind the rounded part off (shorten the wrench) with very frequent cooling in water so the heat of grinding doesn't take the hardness out of the tool. Always get the wrench all the way down into the hex hole, always hold it straight, and if too tight, don't just keep twisting until the hole is rounded.
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post #8 of 17 Old 04-19-2017, 09:44 PM Thread Starter
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Quote:
Originally Posted by richlandrick View Post
Is it (or was it) a mushroom style hex head?
Yes.

I'd post a picture but I've been having an issue with getting pics from my Google Photos account to appear.

It sounds like my best bet is grinding a slot with my Dremel and using a big screwdriver on it.

Luckily, I don't believe the bolt is seized or stuck, so I don't think it'll take much coaxing to get out once I have a way of turning the bolt.
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post #9 of 17 Old 04-19-2017, 10:35 PM
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Thread

Quote:
Originally Posted by bajakirch View Post
Yes.

I'd post a picture but I've been having an issue with getting pics from my Google Photos account to appear.

It sounds like my best bet is grinding a slot with my Dremel and using a big screwdriver on it.

Luckily, I don't believe the bolt is seized or stuck, so I don't think it'll take much coaxing to get out once I have a way of turning the bolt.
If you think the broken off bolt is somewhat loose, then a left hand drill bit will turn it right out once it starts to grab...
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post #10 of 17 Old 04-19-2017, 11:58 PM
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If there is still some of the hex left, take a flat punch with a tip cross-section larger than the hex opening and forge the metal back down. Alternate with a correctly sized and sharp hex bit being driven in the hex hole to reestablish the hex. If you keep at it you can "restore" the hex pretty well and the impact may help to loosen up that bolt so it will come out easier. I would try that before trying to cut a slot.

There may be threadlocker on that bolt. Depending where it is try heating it up (but don't melt the Tupperware)
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