Removing stripped Allen head bolt

[RickK]

Any tips, techniques or recommended tools for removing a stripped seat rail Allen head bolt? These bolts are recessed into the seat rails making it impossible to get an any tool around the bolt head.

To make things worse the power seat will not raise up (which is why I want to remove it) so there is not much room to get any tools to reach the bolt.

[MikeD]

Plasma cutter?

[Jad]

I have been able to cut a slit in the bolt with a hacksaw and then use a screwdriver to remove them.

Also, if it is not too stripped, put the allen wrench in and hit it with a hammer to really set it and it may come out.

[kary]

I have used vice grips if the head is exposed enough to get a hold of it.

[harnishclan]

In a very limited space, this has worked for me before:
1. Pick an allen wrench .5 mm larger than original size.
2. Cut a piece of your allen wrench about 1" long.
3. Use liquid nails or any very strong epoxy type glue and tap/jam wrench piece into the bolt head.
4. Spray some PB Blaster around outside of bolt head.
5. Walk away for at least 1 day!!! (very important step).
6. Use a crescent wrench on the piece sticking above the stripped bolt head. Try not to move crescent up or down or you will loosen the glue bond.
7. Turn bolt TIGHTER just enough to move it.
8. Then back out the bolt.

Allen bolts become much more compliant if you tighten just enough to move them, then back them out. Especially places like 944 manifolds!

[RickK]

Thanks, some good ideas here, with the exception of the plasma cutter which I seem to be fresh out of.

[TheStig]

Sears I believe sells like some sort of easy-out bolt extractor that has counter clockwise threads that will drill into the bolt and extract it that way; or maybe it was clockwise, blah I can't word it correctly at this moment.

But check out Sears. Good luck to you.

[kurquhart]

Sears I believe sells like some sort of easy-out bolt extractor that has counter clockwise threads that will drill into the bolt and extract it that way

Yes, these work quite well. Usually you need to drill a starter hole with a power drill, but a stripped allen screw may not require this step. I have a set of these extractors; PM me if you would like to borrow them.

[TheStig]

of course you can also take Mike's idea and use the plasma cutter should you lose your patience; be warned that you could over cut and give your car the Flinstone upgrade of sticking your feet out to drive it