Stripped Torx Star Head Bolt T595

StuarT595
Tell you what i have done in the past with a side casing bolt is take a torx one size bigger and chamfered the very tip. Then taped it in and cut a new torx thread with it. And tighten just a smidgen first then loose.
Joe.

 

Are you removing or refitting the head? I thought you had to change the head bolts after one use?
I reckon @Pegscraper is on the right track here. The bolt, and the Torx socket are trash so I would weld them together in order to remove the damaged bolt. Allow the bolt to cool down then apply some heat around the bolt on the head with a hot air gun, or blow torch. You are looking to heat the head but not the bolt so don’t go mad or the heat will transfer into the bolt making it harder to remove. You want a cold bolt (contracted) and warm head(expanded) and it should come out ok. Then get a good quality Torx socket and bobs your mothers brother.

 

I get mine from Halfords using my trade card
They sell them individually and have proved to be value for money.

 

these threads are very useful...although sorry to hear of your woes stuart595! It is always good to hear of real world issues and how to get out of a situation!

For what it is worth, being a cheapskate, i tend to buy cheaper tools...but then when one breaks - as i use it the most, i replace it with a quality one...so building up "good tools" for what I use regularly....

I have attempted to use the "easy out" bits before as well (and bought cheap) and they were crap. So, either they are a crap "thing" or a crap concept...I would be interested to hear if "good ones" work well....I haven't replaced those as yet and wonder if it is worth doing so with "good ones"....

I will be interested to see how this all pans out - good luck stuart595!

 

The problem with the "easy outs", even quality ones is they are quite brittle with zero flex. IMO they're designed to remove the remnants of a bolt or stud that's sheared off rather than a bolt that is still under tension, particularly something like a head bolt where high torque is involved. Ideally, you need to drill a pilot hole down into the threaded part of the bolt/stud, then use the extractor/easy out but this won't be possible on a bolt as long as a cyl head bolt.

 

I second this! Pay the extra and buy the Halfords "ADVANCED PROFESSIONAL" tools - they actually feel like good quality, not Snap-on, admittedly, but certainly not Rolson (et. al.). Best of all they're lifetime guaranteed - you break or damage one and they're replaced FOC and (I gather) no quibble, so you'll pay more but pay once!

Case in point :- about a year ago I used my Trade card and a special offer and got one of the Professional sets - not this particular set but something very similar ...

https://www.halfords.com/tools/hand...lfords-advanced-100-pc-socket-set-735948.html -

A couple of weeks ago I needed a hex key socket and discovered that the set I'd bought contained two of one particular size but none of the one I wanted so it had obviously been omitted at production. I took the set in, explained the problem and they unhesitatingly went to the back of the store and brought out the correct part - no question, no problem. They even provided a receipt showing FOC provision. I went to walk out when the assistant said "Oh, you may as well take the duplicate piece with you - it is yours, after all!" They could have as easily put it back on the store shelf and sold it in place of the one they'd given me but it was offered so I took it - never know when you might need that extra!

I don't rate Halfords particularly highly and their prices are not exactly "motor factor" but I can't fault their service on this occasion and, so far at least, can't fault the 'Advanced' range tools.

 

I'll find out soon I've got to take a broken advanced tool back
I'm expecting a shit fight as their 4 year battery guarantee isn't worth anything

 

Well, I'll be interested to hear how you get on - and which store you use. Good luck - hope it all goes OK.

 

No problem at all replaced it
Much better than the 2 year old battery with its 4 year guarantee fight I had 6 months ago ended up telling them to stick the battery where the sun don't shine

 

A lot of head bolts today are designed to stretch when used so it is good practice to replace them as well, I have had success with two types of extractors: short type and Hurlinger type not the usual run of the mill types, but if you do not won't to purchase these maybe a Hex key socket would fit into the Torx head I have also had good results that way.

 

The other option is to weld a nut on top of the knackered Torx bolt, filling the threads of the nut and the hollow in the bolt with weld leaving the outside free for a socket to get a good purchase.
Looks like the person who put those Torx bolts in didn’t use the correct size tool, easy done with Torx.