Stripped Torx Star Head Bolt T595

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

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  1. StuarT595

    StuarT595 Active Member

    Nov 19, 2020
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    #1 StuarT595, Dec 10, 2020
    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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    #2 StuarT595, Dec 10, 2020
    What about dremeling it out to create an allen?
     
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  3. Pegscraper

    Pegscraper Elite Member

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    #3 Pegscraper, Dec 10, 2020
    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

    tcbandituk TC
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    #4 tcbandituk, Dec 10, 2020
    Mole Grips :)
     
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  5. Old dumb arse

    Old dumb arse Noble Member

    Mar 28, 2020
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    #5 Old dumb arse, Dec 10, 2020
    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

    Nov 19, 2020
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    #6 StuarT595, Dec 10, 2020
    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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    #7 StuarT595, Dec 10, 2020
    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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    #8 Pegscraper, Dec 10, 2020
    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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    #9 StuarT595, Dec 10, 2020
    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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    #10 Red Thunder, Dec 10, 2020
    edit - posted in wrong thread
     
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  11. StuarT595

    StuarT595 Active Member

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    #11 StuarT595, Dec 10, 2020
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  12. andypandy

    andypandy Crème de la Crème

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    #12 andypandy, Dec 10, 2020
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  13. joe mc donald

    joe mc donald Joe
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    #13 joe mc donald, Dec 10, 2020
    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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    #14 Callumity, Dec 10, 2020
    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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    #15 StuarT595, Dec 10, 2020
    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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    #16 StuarT595, Dec 10, 2020
    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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    #17 Rocker, Dec 10, 2020
    I know its been said weld the broken torx bit into the bolt
     
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  18. tcbandituk

    tcbandituk TC
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    #18 tcbandituk, Dec 10, 2020
    Is it possible to cut a slot in the bolt head?
     
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  19. tcbandituk

    tcbandituk TC
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    #19 tcbandituk, Dec 10, 2020
    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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    #20 Callumity, Dec 10, 2020
    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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