Removing Stripped Counter Sunk Allen Key Bolts Repair Guide

Difficulty

Moderate

Steps

1

Time Required

                          30 minutes            

Sections

• Removing Stripped Counter-Sunk Allen-Key Bolts
• 1 step

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Introduction

What you need

Step 1

              Removing Stripped Counter-Sunk Allen-Key Bolts               

• Cut a slot into the screw head.
• Place a screwdriver in the slot and tap with a hammer in the counter-clockwise sense to loosen the bolt.
• Unscrew the bolt with the driver.

Cut a slot into the screw head.

Place a screwdriver in the slot and tap with a hammer in the counter-clockwise sense to loosen the bolt.

Unscrew the bolt with the driver.

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                    Wolfgang                     

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Frank B - Jan 12, 2015

Reply

Use the same technique for Philips or crosshead screws.

Use a grinding / cutting disk, not a saw blade. Apply the rotating cutting disk gently, do not force or it will break.

If this is a toughened steel or stainless steel bolt (much tougher), it will be best to use a reinforced cutting disk.

Use a dusk mask to avoid breathing the dusk from the disk !

(No, I don’t usually, but I should !)

Jamie Mcguire - May 25, 2016

While this works it is very difficult to not ruin the material around the bolt.

What I do is use a torx bit. size one up that is slightly larger then the hole and then firmly tap it in. atttach your drive handle a turn slowly while pushing down. this will normally break it free.

Also before your get to this point try putting your allen key in the hole and smack it with a hammer. sometimes the force of the hit will cause the metal to “break” enough that the allen screw wont strip.

Karl Kaufmann - Jun 8, 2017

Reply

There are also specifically designed screw extractors made for this. These tools are generally two-sided: one side is used to drill the hole, while the other is inserted to extract. If the process works, the surrounding area is undamaged.

Tushar Pednekar - Dec 14, 2017

Reply

Use another Allen bolt to weld over it and then you can easily remove the Allen bolt with the help of Allen key

Tushar Pednekar - Dec 15, 2017

Reply

And if for any reason if you can’t weld then just drill the head of the Allen bolt so it’s shears off. And then u can easily remove the rest