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Thread: Removing a rounded torx bolt

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    At Work formula400's Avatar
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    Default Removing a rounded torx bolt


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    I need to remove the heal plate on my Triple to fit the quickshifter but it has a rounded Torx bolt. For once it was not me,
    How do I remove this?

    Cheers




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    Should Get Out More KungFooBob's Avatar
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    Default Re: Removing a rounded torx bolt

    Hammer the next size up torque bit into it.

    Cut a slot in it and use a big screw driver.

    Drill the head off it and use a stud extractor.

    Harsh language.

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    At Work formula400's Avatar
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    Default Re: Removing a rounded torx bolt

    how can i cut a slot in it? the hole is proper round inside, i tried with a hack saw but its old so might need a new one

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    Should Get Out More KungFooBob's Avatar
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    Default Re: Removing a rounded torx bolt

    Junior hacksaw, or a cutting disc on a Dremmel (or similar).

    You could always try to 'drift' it with a hammer and punch, but you'd risk marking the heel plate.

    If you drill the head off there's a chance that the release in pressure would allow you to unscrew the rest easily... if it was just tight, rather than seized.

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    At Work formula400's Avatar
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    Should Get Out More KungFooBob's Avatar
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    Default Re: Removing a rounded torx bolt

    BTW, I'm a numpty, I'm sure there's a proper way to do it. A real engineer will be along shortly.

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    Should Get Out More Screwdriver's Avatar
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    Default Re: Removing a rounded torx bolt

    Quote Originally Posted by KungFooBob View Post
    BTW, I'm a numpty, I'm sure there's a proper way to do it. A real engineer will be along shortly.
    No, I'd be at it with a cold chisel to knock it around. If you can get one of them out, the plate should shift and allow the other to come out a lot more easily.

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    Default Removing a rounded torx bolt

    Quote Originally Posted by Screwdriver View Post
    No, I'd be at it with a cold chisel to knock it around. If you can get one of them out, the plate should shift and allow the other to come out a lot more easily.
    going to google a cold chisel, one comes out ok

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    At Work formula400's Avatar
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    Default Re: Removing a rounded torx bolt

    https://www.amazon.co.uk/Stanley-418...old+chi&sr=8-3


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    Should Get Out More Screwdriver's Avatar
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    Default Re: Removing a rounded torx bolt

    You may find that a new sharp one will cut a slice clean off which is not what you really want. Once you've got a decent size nick in the edge of the screw, swap it for a simple dull punch or strike through screwdriver.

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    Default Re: Removing a rounded torx bolt

    Quote Originally Posted by Screwdriver View Post
    You may find that a new sharp one will cut a slice clean off which is not what you really want. Once you've got a decent size nick in the edge of the screw, swap it for a simple dull punch or strike through screwdriver.
    Cool, will do thanks.

    Just wait for the thread where itís gone
    Through the heal plate and frame and chopped the bike in half


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    Default Re: Removing a rounded torx bolt

    Almost always a good start is oil then sometimes battering the next size up torx bit into it works, better with an old style hit with hammer impact driver.
    Then cutting a slot in it with a dremmel is another option you can do if that fails, then battering it with an impact driver.
    With luck one of those works cos for me the later options start to be more of a pain in the arse, drilling/grinding the head off or cutting/drifting it with a cold chisel.

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    Should Get Out More maccecht's Avatar
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    Default Re: Removing a rounded torx bolt

    I find that when you get this scenario cutting a slot with a Dremmel then using an impact driver gets the job done never had much luck using chisels or punches unless it was on a large bolt head.

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    Should Get Out More Screwdriver's Avatar
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    Default Re: Removing a rounded torx bolt

    If one of the screws is out, surely you can knock the heel plate around to loosen the stuck one.

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    Default Re: Removing a rounded torx bolt

    can i ask the question

    how the hell do you fubar a torx bolt, unless using the wrong sized bit. i've spiralled a torx allen key trying to undo an egr on a transit, but the bolt was fine.....stuck fast but fine.

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