Stripped Torx Star Head Bolt T595

Discussion in 'Technical Help' started by StuarT595, Dec 10, 2020.

  1. StuarT595

    StuarT595 Active Member

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    Oh, dear...not holding out a lot of hope here!
    The head bolts on my T595 have been used before and are worn. They’ve all cracked half a turn...but on the second round one of the bolt chewed, taking two of the teeth off the star bit with it.
    I don’t think it’s worth trying a new bit, it would only trash it, so what are the options now?
    Would you carry on a couple of turns with the rest and maybe then dremmel the top off it?
    I hear about cutting slots on lesser bolts, but can’t see that working on head bolts that are still massively torqued.
    It’s a corner bolt, in case that’s relevant to head distortion, etc.
     
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  2. StuarT595

    StuarT595 Active Member

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    What about dremeling it out to create an allen?
     
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  3. Pegscraper

    Pegscraper Elite Member

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    The bolt is obviously trashed so arc weld a nut or the old torx bit to it. Just take precautions for flying sparks and spatter. Drilling out and using an extractor is an option but on a tensioned head bolt you'll need luck on your side.
     
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  4. tcbandituk

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    Mole Grips :)
     
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  5. Old dumb arse

    Old dumb arse Noble Member

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    Lube and Maybe tighten the good bolts again would relieve some of tension on the bad bolt. Left handed drill bits might be last resort
     
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  6. StuarT595

    StuarT595 Active Member

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    Cheers, Pegscraper...wouldn’t the heat damage the alloy head, though?
    Would tapping a reverse-thread bolt into it be another option do you think?
     
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  7. StuarT595

    StuarT595 Active Member

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    Many thanks for that, much appreciated.
    What’s the practice with left-handed drill bits, is that the same as putting a left-handed bolt into the shaft of the head bolt?
     
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  8. Pegscraper

    Pegscraper Elite Member

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    Looking at the bolt pattern on your engine they look fairly easy to get to with the cams out of the way. Arc welding is a very localised heat source compared to gas. There is heat soak of course but not enough to cause damage IMO. I've used this on a car alloy head bolt and it worked. I used a piece of a fibre glass fire blanket as a shield.
    There isn't much depth there to tap a LH thread into the bolt head but it's another option. If the bolt has a steel washer under it, yet another option would be to carefully grind or drill off the bolt head leaving a stud to remove when the head comes off.
     
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  9. StuarT595

    StuarT595 Active Member

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    Many thanks for all your suggestions...it’s beginning to feel like I have options again :)
     
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  10. Red Thunder

    Red Thunder Crème de la Crème

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    edit - posted in wrong thread
     
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  11. StuarT595

    StuarT595 Active Member

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  12. andypandy

    andypandy Crème de la Crème

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  13. joe mc donald

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    Stuart595.
    Yes I have used the easy outs and they are a bad idea. They tend to snap and when they snap in the bolt you won't even be able to drill. I still use them but if a bolt shows extra resistance I take them out. As said here before i would rather drill or Dremel the head of the bolt and try moulgrips.
    Joe.
     
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  14. Callumity

    Callumity Elite Member

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    Those easy outs are not that easy to use. Is there enough clearance at the corner to use a Stilson (pipe wrench?) I have used them on vehicle brake bolts where heat has accelerated corrosion. Leverage tightens them.
     
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  15. StuarT595

    StuarT595 Active Member

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    Cheers, Joe,
    I guess I’m looking to approach things in stages, and the ‘if it looks like snapping stage,’ may be a valid part of a spiralling journey to drilling the head off and risking warping the head from the sudden release.
     
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  16. StuarT595

    StuarT595 Active Member

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    Sadly not...it’s tight in there and the bolt top is domed and barely 5-7mm proud, and well protected by other head structures.
     
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  17. Rocker

    Rocker Elite Member

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    I know its been said weld the broken torx bit into the bolt
     
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  18. tcbandituk

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    Is it possible to cut a slot in the bolt head?
     
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  19. tcbandituk

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    A pic might be a good idea, to see what the issues are with various techniques...
     
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  20. Callumity

    Callumity Elite Member

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    OK. Before ‘going large’ I would degrease the bolt (nail varnish remover!) and tor’s bit and araldite them together and leave overnight. If you have an impact driver to unscrew even better.
     
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