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    Allen Screw Removal
    by onetenor πŸ‡¬πŸ‡§ ( Sub-Lieutenant)
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    nick
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    πŸ“ Allen Screw Removal
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    Country: πŸ‡¦πŸ‡Ί Australia
    Online: 2 months ago
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    I know it is a long shot but what you need is a spark eroder.
    Regards, Nick.
    onetenor
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    Country: πŸ‡¬πŸ‡§ United Kingdom
    Online: 23 days ago
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    Thanks Boaty but can't slot them as they are deeply recessed. I don't think any glue will work either even the plastic steel I have.πŸ‘
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    BOATSHED
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    You could always try super gluing a near as allen key into it and then try undoing it. if it doesn't some out you can remove the allen key with deactivator before you try anything else that would damage it too far. Or try using a Dremel tool and cut a slot for a screwdriver.
    BOATSHED
    Ianh
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    Country: πŸ‡ΏπŸ‡¦ South Africa
    Online: 25 days ago
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    Try using a left handed drill I have a couple from Tracey Tools Devon. Very Useful
    Only old in years not mind or soul.
    onetenor
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    Much as i thought Doug Ta!πŸ‘
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    RNinMunich
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    Country: πŸ‡©πŸ‡ͺ Germany
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    "the bolts have a plain shank so no danger of thread damage"
    Well John, in THAT case you're laughin' 😁
    Run an HSS drill up 'em (They don't like it up 'em you know! 😲As Cpl Jones would sayπŸ˜‰) as mentioned above, the remains of the hex will keep the drill centered. Start with a small pilot hole perhaps.
    Good luck, Doug 😎
    Young at heart - slightly older in other places πŸ˜‰ Cheers Doug
    onetenor
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    Trouble is I can't access all my bits just now or I might try tapping in a spline (or two).On big stuff I would throw down a weld until I could grip it. Anyway a chance to use my new Mini Drills. Thanks again to all.πŸ‘ BTW Ste the bolts have a plain shank so no danger of thread damage.😜
    onetenor
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    Thanks chaps. All good ideas some of which will try. it has to be remembered I am chair bound so working "a la main"so to speak. Heat and oil /cooling has been tried. A very hot radiator to hand LOL. about 85 C. I think ball burrs could be the answer. They will cut through stainless.Eventually. Keeping flat mills central may be hard without a press of some sort. No current access to left handed drill unfortunately. I'll get there one way or three.πŸ˜πŸ‘
    steve-d
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    If there is nothing left to grip in the holes I would next try a left handed drill. The vibration, heat and left hand direction may unscrew the bolt.
    Which ever direction drill you use the hole in the bolt head will keep it centred. Start with a smaller size and drill deep enough to be just below the head. Go up a size and drill again but don't get to close to the bolt thread diameter. Your ideal situation will be that as you get close the head will snap off. You could drill close then drive a screwdriver bit in and use that to snap the head off.

    Steve
    1
    RNinMunich
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    Country: πŸ‡©πŸ‡ͺ Germany
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    Good idea Colin πŸ‘
    Think you already tried the 'hammering' method didn't you?
    I got the impression from you that there wasn't enough hex form left for that to work!
    Cheers, Doug 😎
    PS The fact that someone rounded out the hex heads suggests to me that the bolts might be seized in anyway πŸ€” making success with improvised tools unlikely.
    1
    Young at heart - slightly older in other places πŸ˜‰ Cheers Doug
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