stupidity

[caddy0150]

so i get this idea that im going to lower my tower on my 2005 24v i loosen all the bolts except for the one hex head bolt on the front runner heading forward that bolt seems tight so i break off the allen wrench in it and cant get it out i try several different ways including drilling but i have no drill that can cut the back way through the bolt or front way thru the allen key piece thats stuck in the bolt any ideas???? maybe ill just never put it down but would like to get this bolt out

[ajholt7]

Can you post a pic. Maybe that would spark some ideas.

[caddy0150]

picture this a screw in a hole with the head full of a snapped off allen key

[ajholt7]

In that case. Get a carbide bit and an easy out. Or if all else fails weld a nut on it and use a socket.

[MTtigekid]

I second the welding idea

[caddy0150]

weld a nut where theres no way to its in a hole ...the drill is the way what kind of bit do i need i tried cobalt and titanium??

[bforsythe]

Caddy, Ive been there. You are screwed. That bolt has obviously siezed. So once you get the head off you still may need to drill the threaded portion out. I ended up with a grinder with a round bit. If you are able to get the allen out try using a torx bit and a breaker bar. Mabye you will get lucky and break the head off the bolt. Good luck just be patient.

[chpthril]

So let me understand, the head of the allen wrench sheered off in the head of of the allen bolt you are trying to remove?

If so, dont try to drill the allen, they are hardened. Instead, use that to your advantage. Take a chisel and try fracturing the broken piece of allen wrench. It may break into more pieces same as it broke the first time.

[caddy0150]

what about drilling from the back side or maybe just leaving it alone do you think a chisil will break it out its so small

[chpthril]

Post a pic or 2 and maybe we can come up with more ideas.

[ajholt7]

weld a nut where theres no way to its in a hole ...the drill is the way what kind of bit do i need i tried cobalt and titanium??

That is why I said post a pic. As far as bit you can a carbide bit to drill that hardend Allen wrench if you can stay on center.

[SPBFAN]

There is a tool out called a magnetic induction heating unit. OTC makes it part number 6650 It is a pricey machine though. You can use this to heat up the bolt and the fractured piece of allen wrench. Because it is magnetic you can pinpoint the heat to a specific area and you will not have flame heat so you will not burn the powder coat or anything from the tower or fiberglass. You might be able to find someone who has a machine that can help you. I have the machine and it heats the metal to a bright red. Just an idea. This will also heat up metal under or through things you do not want to heat up like fiberglass panels but the Magnetic induction will heat up any metal with in a specific range of the probe. It works great on taking out dents from cars with out damaging paint. It does not work to well on aluminum though Just stainless and regular steels.

http://www.otctools.com/products/mag...heating_system

[caddy0150]

tn.jpg

[caddy0150]

as you can see its really not good

[chpthril]

[ATTACH]18309[/ATTACH]

Can you post up an un-cropped pic of that part of the tower? That looks like a pivot point, in which case, there is nothing to take out and that pivot bolt is probably installed with red (permanent) Loc-Tite.