Bar end weight removal?
 

Anyone got ideas on how to get the bolts out other than drilling? The phillips head on both are totally rounded.

Re: bar end weights
 

I'm not sure if you meant to include this in 'drilling' but screw extractors are the way to go.

I had one of my bar ends snapped off leaving just threads flush to the surface at the end of the bar. I got a set of screw extractors similar to this (link) but with a t handle for around 5 pounds on ebay. Made the job easy.

You drill a small pilot hole for it to thread to and then because of the way it is reverse threaded when you screw it counter clockwise it self taps itself into the screw. You keep turning it counter clockwise and eventually it wont thread any further and because you are still turning counter clockwise you end up undo-ing the screw.

The beauty is of course it is all the time keeping the pressure on making sure it is getting as much of a grip on the screw as possible.

Re: bar end weights
 

You could get a dremel and cut a flat groove in them so they can take a flat end screwdriver?

Why no drilling? Easiest way to deal with this is drill the head off, withdraw the bar-end weight, and remove the rest of the screw with mole grips.

Replace with stainless allen head countersunk machine screws

Re: bar end weights
 

+1 drill the head off, then grip the remains with a mole grip.

You'll be amazed at how seized they get, mine was, as Mr Suzuki used no grease on assembly.:rolleyes:

Buy some stainless countersunk allen bolts to replace both. I got mine off t'Bay :santa:

Re: bar end weights
 

Sorry Tam, youn said exactly what I said :stupid:

Re: bar end weights
 

They are made from cheese and easy to drill the head off :D

Re: bar end weights
 

Be very careful with those horrors - they work a small percentage of the times they're used and every single engineering shop has plenty of experience of removing broken screw extractors.

Tapered ones are the worst.

OP: Drill just the head off, remove the weight and there will be an inch of bolt to grip so you can remove it.

Re: bar end weights
 

Really? I will admit I have only had to remove 4 or 5 bolts with them but I found them great in use. On one bolt it had been bent and snapped off so that half was sat in the threads but applying pressure to each side of the threads making it absolutely stuck. It had about 1cm of 'threaded bar' hanging out the end and when i mull-gripped that to turn it and unscrew it, it literally snapped off leaving it flush to the hole. At which point the screw extractors did the job fine.

For future reference. What happens when they 'break'? Do the threads on them die? Would probably useful to be in the know about it, then I can watch out for tell tale signals!

Would be one thing to have a bolt thread or round. It would be another entirely to embed a screw extractor in there as I try to remove it!

Re: bar end weights
 

Yes, because you won't be able to drill it out :rolleyes: Most probrably you'd have to get it spark erroded, to get it out.

I agree with SS, why use one, when you can drill the head off this bolt easily.

If you couldn't then use the extractor, but it would be my last option.