Rounded Hex Bolts
 

What are the different techniques I can use to remove a rounded hex headed bolt (made of something not dissimilar to swiss cheese)? :mad::mad:

I always find it helps if you headbutt a wall several times whilst screaming expletives at the top of your voice... usually followed by sulking and getting someone else to fix it :o

No help I'm afraid, but you have my sympathy ;)

Already gone through the self-harming and profanity stage, am now in the process of trying to be clever and make an even more serious mess, before I finally resign to taking it to someone who isn't a numpty! :mad:

Do you have good access to it?

If you could cut a small groove in the outer edge, you may be able to tap it with a screwdriver/chisel and (small) hammer to get it turning.

Dunno if that makes sense.

I've managed also to get a screwdriver (another bodge) that is like half a millimetre too big for the hex head... tap it in so it's snug and then try turning that... even better if you have a screwdriver with a spanner attachment thingy-me-bob

I'll try to think up a 3rd bodge, should all else fail.

Believe it or not, its the middle bolt on the top yoke of my 749 :( so access isn't great.

I'm thinking of drilling a small hole in it, and tapping a smaller hex socket into it? :puzzled:

try tapping a torx drive into the head of the bolt -it'll have to be a tight fit and then with luck the tapping and the grip of the driver when turned will loosen it----its worked for me in the past

Cool. I'll try that. Its this bolt:



What is the correct torque value for it?





[Edited on 11-6-2005 by khu996]

Ooooooh, that doesn't look like a nice one to round off, you poor sod!

sorry mate cant help you out with that one(the torque)--not familiar with 749--:puzzled:

:saint: Poor bugger,For a 749,23Nm (+-10%) For the steering head screw according to my workshop manual:saint:



[Edited on 11-6-2005 by swannymere]

I'd go for the torx method as well. Try and tap one in that is slightly bigger than the hex hole and hoepfully it will cut into the hole and allow you to turn it. Strange because I had exactly the same problem with my 748 today when trying to remove an exhaust hanger!

Cheers lads. Will give the torx method a go.

Swannymere, where did you get the workshop manual from, and is it any good?

:saint: Ducati dealer,£55,not cheap,but will probably pay for itself:saint:



[Edited on 11-6-2005 by swannymere]

I rounded off the inside hex of a bolt tonight luckily on the bracket that holds the pannier frame on. I removed it together with the A bracket that it was bolted to drilled a small hole right through the bolt then used a stud extractor. I was relieved to see the little bar steward come out. I would like to thank 3X for using about 300 million newton metres to tighten up such a poxy small screw. Good luck, Im sure Halfords sell stud extractors.

Had this happen to a sump plug - right ******* to get out. The only thing that touched it was a set of extractors from Snap-on tools. Very expensive, but I have used them countless times on Ducati cheese screws, and always with success.

When using extractors, you can also try using a plumbers freeze spray to make the offending bolt contract and loosen.

Good luck
Dave.

You can also use a pin punch that is larger than the head of the bolt. Hold the punch over the head of the damaged screw and hit with large hammer. This will get the shape of the hex back (if not too badly rounded). Then use an impact screwdriver with a hex bit.

Has worked for me in the past.

Good quality extractor are good tools as well.