Argh! Stuck bolt on exhaust (now rounded smooth)

[v8s&2wheels]

Was taking the end caps off the 2 mufflers on my zx10r today so I could repack them. Only to have one little bolt decide not to play friendly. It was a 3mm allenkey bolt, and has now taken the form of a 4mm perfect circle. Had the wd40 on it, got the mrs hair dryer for some heat, banging with a hammer.. None of which worked.

Does anyone have a spare small easyout lying around, or anyone with some good know how can do that can possibly remove this stuck bolt for me?

And unfortunately the muffler is welded at the inlet end, so cant even just take it off that way to repack.

[Rosco]

Drill the heads, remove caps and remove the rest of the bolt with a pair of lock pikers or something similar will be the easiest way now.

[Codyg]

Got a set of these from Bunnings to remove a rounded exhaust shield bolt. Was out in 5 minutes
Extractor Screw Sutton 5pce Set 92369 I/N 6360083 | Bunnings Warehouse

[kennyboy]

Can you cut a slot in the head and use a flat screw driver

[v8s&2wheels]

Got a set of these from Bunnings to remove a rounded exhaust shield bolt. Was out in 5 minutes
Extractor Screw Sutton 5pce Set 92369 I/N 6360083 | Bunnings Warehouse

Thats bloody cheap. Paid $45 for a set nearly exactly the same (made by powerbuilt) in NZ 3 years ago.

Off to bunnings for second trip today haha. Hope the little 18v drill will be powerful enough.

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Can you cut a slot in the head and use a flat screw driver

Tried that. Only have my drill and managed to snap the two drill bits that were small enough to make a slot with. No angle grinder at the mo as waiting for house to finish before i buy all my tools.

[Codyg]

Thats bloody cheap. Paid $45 for a set nearly exactly the same (made by powerbuilt) in NZ 3 years ago.

Off to bunnings for second trip today haha. Hope the little 18v drill will be powerful enough.

Its good they were cheap, one is now stuck in the bolt and will not budge haha. Should be able to get it out with a vice

[kennyboy]

Argh! Stuck bolt on exhaust (now rounded smooth)

Thats bloody cheap. Paid $45 for a set nearly exactly the same (made by powerbuilt) in NZ 3 years ago.

Off to bunnings for second trip today haha. Hope the little 18v drill will be powerful enough.

- - - Updated - - -



Tried that. Only have my drill and managed to snap the two drill bits that were small enough to make a slot with. No angle grinder at the mo as waiting for house to finish before i buy all my tools.

Making slots with drills rarely works well...
Can't get vise grips on it or anything? Is it in a hole?

Have a nice pointy center punch and a hammer? Try and turn it out by punching around the edge and then directing the force to the undo side of things?

I would come help but I'm not going all the way to piara waters for a two minute job

[thro]

Vice grips if you can.

easy-outs in my experience (especially small ones) just break off and then you need to drill through easy-out.

Also, apply heat (blowtorch)

[Halo_2]

Got a set of these from Bunnings to remove a rounded exhaust shield bolt. Was out in 5 minutes
Extractor Screw Sutton 5pce Set 92369 I/N 6360083 | Bunnings Warehouse

There a heap of shit and tend to snap, I learnt my lesson with exhaust bolts/seized bolts is to use a impact driver.

[Macca]

Try and buy a decent impact driver now though, i used an impact driver my dad bought for years till it finally gave up its ghost. New one broke within a week

[Falcore]

Get the screwdriver which goes all the way through the handle with a bashy end. Bunnings normally has them. Full set isn't very expensive (plus they're bloody handy).

Get a flat blade one a smidgen bigger than the hole. Apply excessive force in terms of hammer to said screwdriver to mash it into the head.

Then use vice grips or something similar to undo. This method works surprisingly well.

[Falcore]

Argh! Stuck bolt on exhaust (now rounded smooth)

Reverse direction drill bit is another option.

In the future buy a decent set of 1/2inch drive impact Allan key set. Ever since I got a set I've never had a Allan head give me grief.

[Desmo]

Don't listen to anyone else, listen to me first.
Take a socket that is a bit undersized for the now rounded bolt and bash it over the head with a hammer.
Undo it.
Result.

[v8s&2wheels]

Reverse direction drill bit is another option.

In the future buy a decent set of 1/2inch drive impact Allan key set. Ever since I got a set I've never had a Allan head give me grief.

1/2 inch impact drive on a 3mm allen head? Never thought that would work haha.

Got the bastard. Charged the drill and drilled off the head. And for some reason the threaded stud left behind I could unscrew with just my hands. Go figure....

[Falcore]

Yep even that size works a treat. The edges of the tool don't bur over at all and stuff the head