Allen key screws rouding off - what to do next?

[skithepowder]

The other day I went to undo one of the allen key bolts holding on the little black infill panels and it was so bloody tight that in the process of getting it off I could feel it rounding the allen key hole off, fortunately it didn't round it off completely and it's still useable.

Thought I'd have a look at taking the baffle out of my new scorpion can and again it's so bloody tight I can feel the same thing happening. So my question is 1stly - what is the best way to undo these damn tight or unused for a while allen key screws without rounding them off? And if I do round them off what can I do next to get it out, cos it's not like a bolt that I can saw the head off and it'll just slip out! Thanks!!

[maviczap]

Not a lot you can do to help, apart from maybe giving the allen key a couple of sharp taps with hammer to loosen any corrosion.

Others may have other tips.

When you replace them put a bit of coppaslip or a dab of grease to lube the threads, helps no end

[SVMAT]

Penetrating fluid and some decent allen bits for wratchet or decent allen keys. Most bolts get rounded by poundland allen keys. As for getting the rounded ones out, you can saw a slot to use a screwdriver or drill the head off. Ive found alot of bolts with rounded heads come off with an impact driver and the right bit.

[maviczap]

I aslo remember in last months Ride mag, one of their featured mechanic's used torcx bit to remove allen heads which had rounded off. Said he'd never failed to remove one bolt using this method. Just use one of the right size to fit the allen bolt.

I did a similar thing by cutting down an easy out until it was the right size to fit the head.

http://automotivetools.co.uk/images/get_image.php?mode=full&image_name=STW44KTXT10

[warmshed]

Dip the end in some grinding past first can sometimes give better grip too. I agree that an impact driver can often help.

[Sid Squid]

Get a flat, square ended punch, that's larger than the socket, put it squarely on the end of the damaged socket screw and tap it firmly, remove and check the effect. If you've got it right you'll have started the process of reforming the outer end of the damaged recess which will make the tool fit better, (it likely won't be perfect - this is mechanics, not magic), if the tool still doesn't fit well try a few more taps, trimming your angle of attack to the less well formed parts of the recess.
Also the tapping of the screw will have the effect of loosening it slightly.

[GagginForraPint]

Some allen keys have ends that you can use at an angle, can't remember what the name of them is, if the screw is tight make sure you use the end that is a true hexagon

[dirtydog]

Some allen keys have ends that you can use at an angle, can't remember what the name of them is, if the screw is tight make sure you use the end that is a true hexagon

Ball end allen key

[Webber]

If they do round you can use the hex way or just saw or grind a small indent in the top of it and unscrew it with a flat head screwdriver. Easy and takes seconds to do!

[chilli]

Tip from my old man. When you have a tight bolt/screw that doesn't want to undo, try TIGHTENING it a crack, sometimes this will break the seal when pressure the other way won't. (don't ask my why)

Not 100% effective but has worked for me several times in the past.

[muzikill]

Cutting a slot in it wont be easy, am i right in thinking that the bolt is recessed?

[Big Bad Al]

plus one for the torx tip - I have done that myself on the same bolt holding the grey infill panel and it worked a treat. I use copper ease always and the bolt was still too tight, hence the rounding. Good tip.

[warmshed]

I had to run a tap through that thread on my son's bike when I removed the panel. the bolt was very tight when removing it, copperslip/PBC is a must when replacing bolts. Good luck removing your bolt.

[skithepowder]

Cheers for all the advice guys, yeah without going and taking a look I think cutting a slot in the inpanel alllen bolt would be very difficult! At the moment, that one is still working, but I think I might have a look into the torx thing as I'm sure it's gonna round off soon, you can feel it slipping 1/2 the time. The exhaust one, not too important at the moment, cos it's loud enough for me with the baffle, but it'd be nice to know what it's like without! I like the idea of tightening a bit first to break the seal, will defo give that a go in future!