Advice needed on removing bad head bolt

[SteveJ]

Well, I was trying to retorque my head, and I got in a hurry. I rounded the inside of a stock head bolt. I could really use some suggestions on how to get it how. My first thought was to use a bolt extractor, but I had nightmares about the thought of breaking it off inside the motor.

Thanks!
Steve

 

[IJ.]

Bolt extractor is going to be about the safest suggestion Steve.

Anything else I can suggest will mean total disassembly of the motor after to remove the fallout!

 

[SteveJ]

Bolt extractor is going to be about the safest suggestion Steve.

Anything else I can suggest will mean total disassembly of the motor after to remove the fallout!

I appreciate the quick reply and affirmation.

I have just enough mechanical skill to break only a couple of parts on each project.

 

[steve_mk3]

IS it completly rounded?
Can you drive something in the hole like a large flat screwdriver then turn it with a pair of vise grips?
how about the next size up and driving it into the hole?

just some thoughts

Steve

 

[mkiiSupraMan18]

Slightly smaller socket and an impact driver?

Hammer/chissel and try to "turn" it that way are the only other ways I can think of. Or get you a set of those Craftsman socket deals for that smae problem. They worked awesome for my LSD swap when the bolts rounded off.

It's a shame you don't really have room on the 7ms to do anything to help things out. Good luck

 

[SteveJ]

Actually, I got those Craftsman sockets for removing rounded bolts just yesterday to remove a different bolt, and the socket worked like a charm. Unfortunately, the head bolt is an allen head design, so I cannot go one bigger. I'm tempted to look at Steve mk3's suggestion of an 11 mm allen head socket (similar concept to your suggestion) as a starting point.

 

[IJ.]

7/16" Allan Key cut off about 25mm/1" long piece and grind a slight taper at the edge of the flats take a hammer and knock it into the damaged boly then use a 7/16" socket to turn it.
(butchery but will work)

 

[mkiiSupraMan18]

You should still be able to get the bolt remover onto an allan head, w/ the way they taper down, I would think it would be fairly simple... but I've never had to do it. O

Before U get really super carried away...

Put an extension on the head of the bolt and give it a few solid hits (obviously don't hit it hard enough to break it or anything) or when you get the 11 driven down to the bottom of the bolt, give it a few good taps. It'll help break it loose. :icon_bigg Works awesome for TPS screws also.

*edit*
^ You know you're a Supra owner when... lol

 

[IJ.]

Never seen an 11mm Inhex socket
(7/16" is close enough)

 

[SteveJ]

You should still be able to get the bolt remover onto an allan head, w/ the way they taper down, I would think it would be fairly simple... but I've never had to do it. O

Before U get really super carried away...

Put an extension on the head of the bolt and give it a few solid hits (obviously don't hit it hard enough to break it or anything) or when you get the 11 driven down to the bottom of the bolt, give it a few good taps. It'll help break it loose. :icon_bigg Works awesome for TPS screws also.

*edit*
^ You know you're a Supra owner when... lol

Actually with your previous post, you inspired me to look on the Sears website. The have some extraction tools designed for boogered screws. I think I might take a trip over to the local store to see if they might work for an allen head.

I appreciate all of the suggestions.
Steve

 

[mkiiSupraMan18]

I'll run out to the garage and check and see if they'll fit... stock head bolt, correct?

 

[SteveJ]

I'll run out to the garage and check and see if they'll fit... stock head bolt, correct?

Thanks for checking. Yes, it's a stock head bolt.

Also has anybody used used a multi-spline extractor?

I found it on the Snap On Tools website at http://buy1.snapon.com/catalog/item.asp?item_ID=10533&group_ID=1262.

 

[mkiiSupraMan18]

I don't have the right one, but I'd put money on a #12 craftsman working out for you. I just got the "metric" set and the biggest I have (#10) doesn't fit. I coulda swore I got the whole set...

I have 0 faith in something like this working...
but hypothetically, for a problem like this could someone get an allen wrench and JB weld it in there, wait for it to set, and remove it that way?

 

[SteveJ]

I don't have the right one, but I'd put money on a #12 craftsman working out for you. I just got the "metric" set and the biggest I have (#10) doesn't fit. I coulda swore I got the whole set...

I have 0 faith in something like this working...
but hypothetically, for a problem like this could someone get an allen wrench and JB weld it in there, wait for it to set, and remove it that way?

Thanks for checking. My set goes up to a #13. Hopefully our sets are sized the same. I noticed differences in sizing when I was comparing them at Sears.

The tricky part will be working down in the head with the camshaft in place.

 

[IJ.]

That's why I suggested an 7/16" Allen Key you can make it as long as needed

 

[SteveJ]

That's why I suggested an 7/16" Allen Key you can make it as long as needed

Thanks! I'll be sure to update on how I manage to get it out.

 

[IJ.]

You just need a slight taper on the leading edge of the Key before you smack it in and it'll wedge in really tightly!

 

[steve_mk3]

7/16" Allan Key cut off about 25mm/1" long piece and grind a slight taper at the edge of the flats take a hammer and knock it into the damaged boly then use a 7/16" socket to turn it.
(butchery but will work)

This is where I would start.
If it doesnt owrk you can try the extractor, but if you try the extractor forst it may make the allen opening even more rounded then this idea wouldn't work.
That would be my approach.

and I suppose you could always weld a bolt onto the rounded bolt and then turn the bolt. I dont have access to a welder so for me that thought was out.

Good luck.

Steve

 

[mkiiSupraMan18]

lol... this reminds me of taking that oil galley cover off...

14mm bolt and a pair of vice grips. lol

Damn I love Supras. :icon_conf

*edit*
So, the JB weld.... any thoughts? Anyone? You can just tell me straight up it's a stupid idea, I wont cry.

 

[IJ.]

SteveMk3: LOL Yep that was my next suggestion but would require a full tear down to remove the crap/spatter from the welder!