How to drill out recessed stripped allen head?
 

So I want to replace my A/C manifold hose, but it mounts to the block and both allen head bolts stripped immediately with hardly any pressure applied.
I am not savvy with my options from here, but it needs to come out. I don't care about the manifold hose that surrounds it.

It is both recessed, and I do not have a straight 90 degree shot at it either so I cannot use an easyout.

Any suggestions on how to get this out?

Two suggestions:

1. Epoxy a hex bit driver in place and after the epoxy dries try removing it; or,

2. Purchase bolt extractors, the type that go over the head of the bolt like a socket. The socket end is fluted internally and grabs the exterior head of the bolt as you turn it out.

Good luck, you will get them out.

If you can procure the one for 13mm bolts, it will grab that allen head.

Similar to the epoxy solution.. weld something to it..a hex key...a socket might be better...

If you can remove more sometimes that is best - does this part actually mount directly to the block or is there a bit in between? If so removal of the bit in between often seems like more work but in my experience it isn't always the case. There's nothing better than decent access.

Whilst I agree with the gluing and welding and gripping options it sounds to me like you're about to remove the head of the screw and leave the thread behind...

Use a reverse drill bit they have them

I was in PNP in Nov, cold was snowing and cold removing the Pressure Plate off a 81 Euro W123 300D. The last bolt of the 6 had the head already stripped.:mad: Did I mention cold? and it was closing time, and a 617 38# FW was almost mine.

Bought the 4 bits set of Triple Square from O`Rileys. come in 6,8,10 and 12mm. With a Hammer I drove home the 8MM into the head of the bolt and she came right out.

Don`t know how much room you have, but this could work for you.


Charlie

Weld a nut on....
 

I have had success with taking a nut, holding over the end of the offending fastener and welding through the hole in the nut with a MIG until it is filled. Then get a wrench on it while it is still hot. The heat of the welding will help loosen the threads.

I had the same problem removing the star head bolt (the last one) trying to remove it. Used a wire welder and welded one of the head bolts just taken out. Hammered the threaded bolt into the stripped head bolt, put a good bead on it. Applied a breaker bar to the star tool and out it came.

Stripped bolt
 

Can you get in there with a die grinder and grind away the bracket surrounding the bolt then grab the remainder with vise grips and back it out. I have also ground a slot into the offending bolt and used a straight screwdriver bit in a ratchet to back out the old bolt. This again only works if the bracket is expendable because you cut the groove into it also. If space is tight dremel makes small cut off wheels. Just takes longer

I'm having the same issue
 

Ps2cho,

I was wondering what method you ended up using to get them out. Yup, I'm having the same problem you had.

I already tried the epoxy route. I used JB Weld and let it cure for 24 hours. When I tried to remove the bolt, the 6mm Allen socket still spun in the bolt.

Buying. Triple square or a torx bit and hammering it in always worked for me.

I've had good luck hammering in a torx socket as well