Sunk, rounded off, torx head screw removal

[Snails]

Hi,

I need to remove a sunk T40 screw, the trouble is that it has been rounded. I have used penetrating oil to try and break the corrosion bond, but now I am stuck actually removing the thing!

I am tempted to hammer a T45 fitting into the top so that it is very snug and go from there.

Before I try that does anybody have any suggestions?

[PhillipM]

Usually easier to hammer a slightly bigger allen key in than the next size torx

[ch427]

Brake disc by any chance?
Hammer in the T45 as suggested, heat may help but if its stuck as bad as the fixings on my mini discs then its drill out time.

[T1pper]

Fill The head with weld (a mig welder is best) and then build it up to a domed blob of weld on the head of the torx bolt.

Next find a large nut that covers the whole head and weld the centre of the nut attaching the torx head and nut as one.

While its still hot remove with a spanner works every time!!!!!!

[Snails]

I will have a stab at hammering the torx in first. If that fails I will pop around my girlfriend dad's and hope he can weld a nut on.

[TallPaul]

I doubt you'll have much luck hammering in a larger Torx, I bet it shatters.
You're better off either forcing in a slightly larger allen key or if the head isnt too rounded get a good quality Torx on a socket and try slightly tightening it and then undo it.

[ridds]

What is access like?

Can you not just drill the head off? remove said component and then use a pair of mole grips to get the remaining thread out?

[VinceFox]

Pic?


Got one of these out of an ignition barrel on a honda triple clamp a few days ago, ended up using a reverse socket stud after cutting the head off and exposing the threaded stud itself.

[Snails]

Okay, I'll heed the advice and try an allen key suggestion first. I will take a picture when the I try the allen key.

[Krikkit]

I've had success with both hammering in a bigger torx and substituting for a hex.

[cpas]

Another option if the head is proud is to hammer a suitably sized socket over the head of the whole bolt. This worked when I was trying to remove the bolts on the CV joint on my Land Rover

[Athlon]

If its holding a disc on get a sharp pointed drift close to the edge a thump it had with a hammer, it may take a couple of decent hits but it will shock loose, once it has it will just wind out.

[smack]

A manual impact driver has got me out of those problems in the past.

[Snails]

Thanks for all the suggestions.

I ended up using a dot punch on the very edge of the head of the screw and whacking it a few times in an anti clockwise direction and 'hey presto' it was free.

Hopefully this helps somebody else: