stripped allen head

[Rossage]

I have a stripped 2.5mm allen bolt head and I'm looking for a quick fix. I know I can drill it out but is there another way? Will a standard (English) size allen key work?

[foofighter]

how bout a pair of vice grips to grab the head and undo it from there?

[destroyer]

I've had great luck using a dremel with cut off wheel to cut a groove into the head and using a flat headed screw driver to unscrew the bolt.

[dstepper]

http://www.wikihow.com/Fix-a-Stripped-Screw
http://www.epinions.com/content_120395959940

NOTE: Google is your friend.

[Rossage]

Vice grips wont fit. Th dremel trick might do it though. Looks like I might be making some noise in the morning

[Shu]

small drill bit and an EZ out...will work EVERYTIME

[socal ridur]

i had a few bolts stripped on my rotor but i used a dremel cut a philips kind of cut in the bolts and used a torx screw driver and a hammer and they came out

[bighit8]

You can use an easy out. I have been a auto mechanic for 15 years. What you do is drill a hole through the center of the broken bolt. You then use a left or right hand extraction tool. If you need more info feel free to ask. I will remove it for you if you are unsure on the method.On the positive, it is a low torque bolt, hence the reason they use a small allen head.Just an idea, always use anti seize on all bolts, stops rust and keeps the threads clean. Before every ride check all your bolts!!!!

[SAR_boats]

Originally Posted by destroyer

I've had great luck using a dremel with cut off wheel to cut a groove into the head and using a flat headed screw driver to unscrew the bolt.

Ensure the fastener isn't seized in the hole. Spray some penetrating oil on the fastener to loosen it up. Wait atleast n hour before proceeding.

Take a #1 EZ-out screw extractor and use a ball-peen hammer to tap it into the head. Twist ez-out couter clockwise to remove the bolt. You can get ez-out screw extractors from Sears

or

Use a cold chisel to make a gouge in the head and use a flathead screwdriver (similar o thedremel tool method) Be warned that if the bolt stripped out from an allen wrench, then it will probably stripfrom flathead too.

[bighit8]

Oh and you might try an over sized torx bit, it might grab just enough.

[PacMan]

If the vice grips don't work, drill it out with a small drill bit and then use an easy-out. Works every time.

[RustyIron]

Originally Posted by Rossage

I have a stripped 2.5mm allen bolt head and I'm looking for a quick fix. I know I can drill it out but is there another way? Will a standard (English) size allen key work?

"Quick fix" will bring you more grief than joy. "Quick and sloppy" is what gets us into quagmires where we NEED to "fix." Now is the time for patience.

So...
Your first instinct is good. If you can find an SAE wrench that you can jam into the metric hole, do so. Don't be afraid to lightly tap it in with a hammer.

Apply torque. If it works, you're da man. If it's starting to deform the metal, stop immediately. Move to Plan B.

Sometimes I like to grind down an Allen wrench to fit the deformed hole. Tap it in if necessary. The same rules apply. If it doesn't work without deforming the metal, move to Plan C.

The Dremel tool suggestion applies here. I'ts a good one. Be careful an deliberate with the metal you remove. Make the grove square with sharp corners, like a brand-new screw.

Not to be a contrarian, but Easy-Outs suc... are not all they're cracked up to be -- ESPECIALLY on small hardware. Easy-Outs are hard material, so when you break it off in the bolt, drilling it out is no longer an option.

If you get to this point, it might be helpful to tell us exactly what you're doing, the materials involved, and accessibility to the bolt.

Good luck.

[Edog]

Hacksaw, groove, screwdriver

[epicriderat]

Yes, drilling is one way, but 2.5mm is small. If the head is not countersunk you can use a small needle nose vise grip and try to get a good bite on it to loosen. Unless it's been overtightened, it should come loose. Trick is, don't just try to wrench the vise grips hard and fast. If you get a good bit be patient and turn slowly to loosen. Remember Righty Tighty, Lefty loosey. And yes sometimes a standard size will work, as long as you get a good fit to not just strip it out further. If the standard is a little bigger, gently tap with a hammer to get it to set into the stripped 2.5mm head. Good Luck

[FyrFytrRyn]

well, id just buy a new one... bike that is.

[DeeZee]

Originally Posted by destroyer

I've had great luck using a dremel with cut off wheel to cut a groove into the head and using a flat headed screw driver to unscrew the bolt.

have done it many times

Also you can use a hacksaw if you have the room

[spookydave]

you better be good with that hand drill if you plan to sink a drill bit down the center of a 2.5mm bolt. That will be a small drill and a small ez out. Break either and you're done.

[northshore]

Originally Posted by destroyer

I've had great luck using a dremel with cut off wheel to cut a groove into the head and using a flat headed screw driver to unscrew the bolt.

^^^^^what he said. I autocross a ton and have used this same method but with a cut off wheel.

[uno-speedo]

Chainsaw. Works every time.

[thephat]

If it is hard to turn, use heat, solvent, and maybe vibration to loosen it up.

I have had good luck with a heat gun which is kind of like a hair dryer but different.

All of the suggestions so far are good. Once you have a hold, you will only need my above suggestions if it's stuck.

Sometimes a torx wrench will jam in the rounded bolt head and work.