stripped-bolt-removal Archives * flexco.com

Stripped Allen bolts are a frustrating problem, but with the right tools and techniques, you can remove them without damaging the surrounding material. In this comprehensive guide, we’ll walk you through the steps involved in removing stripped Allen bolts, using a variety of methods. From using specialized tools to applying extra force, we’ve got you covered. Whether you’re a seasoned professional or a DIY enthusiast, this article will empower you with the knowledge and strategies to tackle stripped Allen bolts with confidence.

Before diving into the removal process, it’s crucial to understand why Allen bolts become stripped in the first place. Over-tightening, using the wrong size wrench, or applying excessive force can all contribute to the stripping of Allen bolts. Once stripped, the bolt’s hexagonal socket becomes damaged, making it difficult or impossible to remove using conventional methods. That’s where our guide comes in. We’ll introduce you to various techniques, including using bolt extractors, applying heat, or even welding a new head onto the bolt. Each method is explained in detail, with step-by-step instructions and clear illustrations to guide you through the process.

In addition to providing effective removal methods, we’ll also discuss safety precautions and preventive measures to avoid stripping Allen bolts in the future. By following the tips and techniques outlined in this comprehensive guide, you’ll be well-equipped to handle stripped Allen bolts with ease. So, whether you’re dealing with a stripped Allen bolt on a bicycle, furniture, or machinery, this article will provide you with the knowledge and confidence to remove it successfully.

Removing with Extracting Tool

An extracting tool, often called an “Easy Out” or “Screw Extractor,” is a specialized tool designed to remove stripped Allen bolts. These tools are typically made of hardened steel or alloy and feature a reverse-threaded design with a tapered end. The tapered end is inserted into the stripped hole, and as the tool is turned counterclockwise, the reverse threads bite into the bolt and create a gripping action. By applying steady pressure and turning the tool, the bolt can be gradually backed out of the hole.

To use an extracting tool effectively, it’s important to choose the correct size tool for the stripped bolt. The tool should be slightly smaller than the inner diameter of the bolt’s head. Once the tool is inserted into the hole, it’s essential to apply firm but controlled force while turning. Excessive force can cause the tool to snap or damage the bolt further.

If the bolt is particularly stubborn and resists removal, it may be helpful to apply a penetrating lubricant or rust solvent to the hole. This can help to loosen any corrosion or debris that may be preventing the bolt from being extracted. Additionally, using a heat gun to warm the bolt can sometimes make it easier to remove, as heat can expand the metal and loosen the threads.

Here are the key steps to follow when using an extracting tool:

Select a tool that is slightly smaller than the inner diameter of the bolt’s head.
Insert the tapered end of the tool into the stripped hole.
Turn the tool counterclockwise with firm but controlled force.
If necessary, apply a penetrating lubricant or heat to loosen the bolt.
Continue turning the tool until the bolt is fully removed.

While extracting tools can be effective for removing stripped Allen bolts, it’s important to note that they may not be suitable for every situation. If the bolt is heavily corroded, damaged, or has been stripped beyond a certain point, it may be necessary to drill out the bolt or use other specialized techniques to remove it.

Removing with Flathead Screwdriver

Inserting a flathead screwdriver into the stripped bolt may be effective in removing it. Here’s a step-by-step guide:

Locate a flathead screwdriver with a tip that is slightly wider than the bolt head’s diameter.
Place the screwdriver tip into the stripped bolt head and align it with one of the bolt’s flats or edges.
Apply downward pressure on the screwdriver while simultaneously turning it counterclockwise to loosen the bolt.
If the bolt remains stuck, try hammering the screwdriver gently into the stripped head to create a better grip.
Continue applying pressure and turning the screwdriver until the bolt is loosened and removed.

When removing a stripped Allen bolt with a flathead screwdriver, keep the following tips in mind:

Tips
Use a screwdriver with a tip that fits snugly into the stripped bolt head.
Apply moderate to firm pressure on the screwdriver to avoid damaging the bolt further.
If the screwdriver slips, try using a rubber band or a small piece of cloth for better grip.

Removing with Pliers

Using pliers is a simple method for removing stripped Allen bolts. To do so:

Choose a pair of pliers with a good grip and position them over the bolt.
Apply firm pressure and turn the pliers counterclockwise to loosen the bolt.
If the bolt is very tight, you may need to apply leverage by using a larger set of pliers or a wrench.

Removing with Bolt Extractor

Bolt extractors are specialized tools designed to remove stripped or damaged bolts. They come in various sizes and shapes to fit different types of bolts.

To use a bolt extractor:

Select an extractor that is slightly smaller than the diameter of the bolt.
Drill a small hole into the center of the bolt using a drill bit that is the same size as the extractor.
Tap the extractor into the hole using a hammer. Ensure it is securely seated.
Attach a wrench or socket to the extractor and turn it counterclockwise to loosen the bolt.
If the bolt is extremely tight, you may need to use a penetrating oil or heat to loosen it before attempting to extract it.

Advanced Techniques for Removing Stripped Allen Bolts

Reverse Drilling: Using a drill with a left-handed drill bit, drill into the bolt in reverse. This can sometimes create enough friction to loosen the bolt.
Hammer and Chisel: For bolts that are severely stripped, a hammer and chisel can be used to create a new slot in the bolt head. This can allow you to use a flathead screwdriver to remove the bolt.
Angle Grinder: An angle grinder can be used to cut a new slot into the bolt head or even to remove the entire bolt head. This is a more destructive method but can be effective when other methods fail.

Removing with Drill and Easy-Out

If the bolt is too damaged for a hex bit or an extractor, you can use a drill and an easy-out to remove it. This method is not as common as the others, but it can be effective if the bolt is badly stripped.

Steps

– Gather your materials. You will need a drill, a set of drill bits, an easy-out, and a hammer.
– Choose the right drill bit. The drill bit should be slightly smaller than the diameter of the bolt.
– Drill a hole in the center of the bolt. Drill slowly and carefully, and make sure not to drill too deep.
– Insert the easy-out into the hole. The easy-out should be slightly smaller than the drill bit.
– Tap the easy-out with a hammer. This will help to loosen the bolt.
– Turn the easy-out counterclockwise. This will remove the bolt from the hole.

Removing with Vise-Grip Wrench

Vise-grip wrenches are a versatile and powerful tool that can be used to grip and remove stripped Allen bolts. To use this method, follow these steps:

1. Choose the Right Vise-Grip Wrench

Select a vise-grip wrench that is the appropriate size for the stripped Allen bolt. The jaws of the wrench should be able to fit snugly around the bolt.

2. Position the Wrench

Place the jaws of the wrench around the stripped Allen bolt and tighten them securely. Make sure that the jaws are gripping the bolt as close to the head as possible.

3. Twist and Remove

Apply force to the wrench and twist it in the direction that will loosen the bolt. Use slow and steady pressure to avoid damaging the bolt or the wrench.

4. Remove the Bolt

Once the bolt is loose, remove it from the surface. If the bolt is still stuck, you can try tapping it with a hammer to break it free.

5. Additional Tips for Using a Vise-Grip Wrench

– **Use penetrating oil:** Apply a penetrating oil, such as WD-40, to the stripped Allen bolt. This will help to loosen the bolt and make it easier to remove.

– **Lock the wrench in place:** To prevent the wrench from slipping, lock the jaws in place by tightening the adjustment screw.

– **Use a cheater bar:** If the stripped Allen bolt is particularly stubborn, you can use a cheater bar to increase your leverage. Attach the cheater bar to the handle of the wrench and apply force.

Pros	Cons
– Versatile and powerful tool – Can be used on a variety of bolts – Easy to use	– Can damage the bolt if not used carefully – May not be effective on all stripped bolts – Requires some force to operate

Removing with Dremel Tool

Utilizing a Dremel tool is an effective method for removing stripped Allen bolts. First, insert a carbide cutting bit into the tool and secure the workpiece firmly. Mark the center of the bolt with a punch or drill bit to ensure precision. While wearing safety goggles, operate the Dremel tool at a low to medium speed and gradually cut a notch into the bolt’s head. Create a deep enough notch so that a flathead screwdriver can be inserted.

Removing with Utility Knife

In cases where a Dremel tool is unavailable, a utility knife can be employed. Similar to the Dremel tool method, mark the center of the bolt head. Carefully carve a groove around the circumference of the bolt using the utility knife’s sharp blade. Ensure that the groove is deep enough for a flathead screwdriver to fit snugly. Once the groove is cut, insert the screwdriver and apply leverage to loosen the bolt.

6. Using a Bolt Extractor

Bolt extractors are specifically designed tools for removing stripped bolts. Choose an extractor that corresponds to the size of the damaged bolt. Insert the extractor into the bolt’s head, ensuring it engages with the stripped threads. Using a wrench or pliers, gently apply pressure to turn the extractor counterclockwise. As the extractor bites into the bolt, it will gradually loosen it.

Bolt Extractor Sizes
M3-M8
M5-M10
M6-M12

Removing with Hammer and Punch

This technique involves using a hammer and a punch to create a new surface for the hex key to grip onto.

1. Start by safety ensuring you have eye protection, as you’ll be hitting metal with a hammer.

2. Position a punch or nail set with a pointed tip in the center of the stripped bolt head.

3. Strike the punch with a hammer with enough force to create a small indent into the bolt.

4. Repeat steps 2 and 3 to create a series of indents around the circumference of the bolt head.

5. Insert a hex key of appropriate size into the indents and try to turn the bolt.

6. If the bolt doesn’t turn, tap the hex key with a hammer to further drive it into the indents.

7. Advanced Technique: If the above steps fail, you can use a larger punch or chisel to create a larger indent. Insert the hex key into the wider indent and use a socket wrench or adjustable wrench to turn the bolt. This method provides more leverage and can help loosen stubborn bolts.

Removing with Cold Chisel

Using a cold chisel is a more forceful method, but it requires careful precision to avoid damaging the surrounding area. Here are the steps to remove a stripped Allen bolt using a cold chisel:

Wear appropriate safety gear, including safety glasses and gloves.
Position the cold chisel at a 45-degree angle to the bolt’s head.
Strike the chisel with a hammer to create a small notch in the bolt.
Continue making notches around the bolt’s circumference, progressively widening and deepening them.
Once the notches are deep enough, use a flathead screwdriver or pry bar to pry the bolt out of the hole.
Clean the hole thoroughly using a wire brush or compressed air.

Alternative Methods for Extracting a Stripped Allen Bolt

In addition to using a cold chisel, there are several other methods you can try to remove a stripped Allen bolt:

Method	Description
Extractor Tool	A specialized tool designed to grip and extract stripped bolts.
Reverse Drill Bit	A drill bit specifically designed to bite into the bolt’s material and reverse it out.
Hammer and Flathead Screwdriver	Place a flathead screwdriver into the bolt’s head and strike it with a hammer to create a notch for extraction.
Heat and Wrench	Heat the bolt with a torch or heat gun and then loosen it with a wrench.
Vice Grips	Clamp vice grips onto the bolt’s head and then turn it out.

Using Heat to Remove

Applying heat to a stripped Allen bolt can help expand the bolt, loosening its grip on the material. This method is particularly effective for bolts that have become stuck due to corrosion or rust.

Preparation:

Gather necessary tools: heat gun, pliers, wrench
Protect surrounding area from heat
Wear appropriate heat-resistant gloves

Steps:

Heat the Bolt: Use a heat gun to direct heat onto the bolt’s head. Focus on the area around the stripped hex socket.
Wait for Expansion: Allow the bolt to heat for several minutes. The metal should gradually expand.
Twist Out the Bolt: While the bolt is still hot, use pliers or a wrench to gently twist it counterclockwise. The expansion should have loosened its hold.
Cool the Bolt: Once the bolt is removed, let it cool down completely.
Clean the Threads: Remove any debris or melted material from the bolt and the mating surface.
Apply Anti-Seize Compound: Before reinserting the bolt, apply anti-seize compound to the threads to prevent future seizing.
Reinsert the Bolt: Carefully tighten the bolt using a proper-fitting hex key or socket wrench. Avoid overtightening.
Wait for Cooling: Allow the bolt and mating surface to cool before using the fastener or applying any load.

Troubleshooting:

Problem	Solution
Bolt doesn’t budge	Increase the heat, use a stronger wrench, or try tapping the bolt with a hammer while applying heat.
Bolt head breaks off	Stop heating immediately. Let the bolt cool and drill out the remaining portion using a drill bit slightly smaller than the bolt’s diameter.
Overheating occurs	Reduce the heat setting and move the heat gun further away. Allow the bolt to cool periodically.

Repairing the Damaged Thread

1. Using a Larger Allen Key

If the Allen bolt has become stripped due to using the wrong size key, try using a slightly larger key. A larger key will distribute the force over a wider area, reducing the likelihood of further damage.

2. Heating the Bolt

Heating the stripped bolt can soften the metal, making it easier to remove. Use a heat gun or a torch to heat the bolt, being careful not to overheat it. Once the bolt is hot, use pliers or a wrench to loosen it.

3. Using a Dremel Tool

A Dremel tool is a versatile tool that can be used to create a new groove for the Allen key. Use a cutting bit to carefully remove the damaged threads and create a new groove. Be sure to use a key that fits the new groove.

4. Using a Bolt Extractor

Bolt extractors are specifically designed to remove stripped or damaged bolts. Insert the extractor into the bolt and use a wrench to turn it counterclockwise. The extractor will grip the bolt and gradually loosen it.

5. Using a Hammer and Chisel

In extreme cases, you may need to use a hammer and chisel to remove the stripped bolt. Use a chisel to create a groove in the bolt head and then use a hammer to drive the chisel into the groove. The bolt should eventually break free.

6. Using a Tap and Die

If the threads of the bolt are damaged, you can use a tap and die to restore them. A tap is a tool used to cut threads into a hole, while a die is used to cut threads onto a bolt. Use the appropriate tap and die to clean up the threads and then insert the bolt.

7. Using a Screw Extractor

Screw extractors are similar to bolt extractors, but they are specifically designed for removing stripped screws. Insert the screw extractor into the bolt and use a wrench to turn it counterclockwise. The extractor will grip the bolt and gradually loosen it.

8. Using a Stripped Bolt Remover Kit

Stripped bolt remover kits contain a variety of tools and techniques for removing stripped bolts. These kits typically include extractors, drills, and taps.

9. Using a Reverse Drill Bit

Reverse drill bits are designed to remove stripped screws and bolts by drilling into them in a counterclockwise direction. This creates a new groove for the Allen key or other tool.

10. Using a Rubber Band

A simple trick that sometimes works is to place a rubber band over the damaged Allen key and then insert it into the bolt. The rubber band provides extra grip, allowing you to loosen the screw or bolt.

How to Remove a Stripped Allen Bolt

Stripped Allen bolts can be frustrating to remove, but there are a few simple steps you can take to get them out. Here’s how to remove a stripped Allen bolt:

Use a larger Allen wrench. If the Allen wrench you’re using is too small, it will strip the bolt even more. Try using a larger wrench that fits the bolt more snugly.
Tap the wrench with a hammer. This will help to break the bolt loose and make it easier to turn.
Use a rubber band. Place a rubber band over the bolt and then insert the Allen wrench. The rubber band will help to grip the bolt and make it easier to turn.
Use a screw extractor. If the above methods don’t work, you can try using a screw extractor. Screw extractors are specially designed tools that can grip and remove stripped bolts.

Tag: stripped-bolt-removal

4 Easy Ways to Remove a Stripped Allen Bolt