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Argh! Stuck bolt on exhaust (now rounded smooth)

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  • Argh! Stuck bolt on exhaust (now rounded smooth)

    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.

  • #2
    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.
    Don't even think about it. You know who you are.

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    • #3
      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

      Comment


      • #4
        Can you cut a slot in the head and use a flat screw driver
        for passing your r-e test see here- http://www.perthstreetbikes.com/foru...-thread-57420/
        for passing your R class test see here- http://www.perthstreetbikes.com/foru...-thread-97314/
        for passing your intermediate excel training coarse see here- http://www.perthstreetbikes.com/foru...course-163460/

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        • #5
          Originally posted by Codyg View Post
          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.

          - - - Updated - - -

          Originally posted by kennyboy View Post
          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.

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          • #6
            Originally posted by v8s&2wheels View Post
            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

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            • #7
              Argh! Stuck bolt on exhaust (now rounded smooth)

              Originally posted by v8s&2wheels View Post
              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
              for passing your r-e test see here- http://www.perthstreetbikes.com/foru...-thread-57420/
              for passing your R class test see here- http://www.perthstreetbikes.com/foru...-thread-97314/
              for passing your intermediate excel training coarse see here- http://www.perthstreetbikes.com/foru...course-163460/

              Comment


              • #8
                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)
                “Crashing is shit for you, shit for the bike, shit for the mechanics and shit for the set-up,” Checa told me a while back. “It’s a signal that you are heading in the wrong direction. You want to win but crashing is the opposite. It’s like being in France when you want to go to England and when you crash you go to Spain. That way you’ll never get to England!” -- Carlos Checa

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                • #9
                  Originally posted by Codyg View Post
                  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.
                  Last edited by Halo_2; 03-12-2013, 05:35 PM.
                  "Some people are like clouds. When they disappear it's a beautiful day"

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                  • #10
                    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
                    Originally posted by CBRsairz
                    assume nothing Macca, I've totally been cockblocked before :spiteful:

                    Comment


                    • #11
                      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.
                      Every one has a story.....

                      http://www.perthstreetbikes.com/foru...updates-82338/

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                      • #12
                        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.
                        Every one has a story.....

                        http://www.perthstreetbikes.com/foru...updates-82338/

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                        • #13
                          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.

                          Comment


                          • #14
                            Originally posted by Falcore View Post
                            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....

                            Comment


                            • #15
                              Yep even that size works a treat. The edges of the tool don't bur over at all and stuff the head
                              Every one has a story.....

                              http://www.perthstreetbikes.com/foru...updates-82338/

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