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Completely stripped allen bolt!

1K views 3 replies 2 participants last post by  Ben-in-Brazil 
#1 ·
I know there`s a ton of info about this but I just feel so helpless that I just had to come here (again) as a last resort. I`m hoping someone can give me some advice about this. I also realize that it`s not a majorly important screw on the bike as well, but I`d prefer to get it out if possible.

It`s the small allen bolt that secures the small left side seat cover to the metal tab on the tank.

I`ve tried the epoxy resin route, even loctite and the rubber band trick all without success. As a last resort I went out and bought a power drill and I have gotten down to a point where I`m quite scared of going any further as I haven`t done this before and don`t want to risk damaging anything else. I`ve used all size drill bits up to 8mm (the thread size is 6mm) so The head of the bolt has a big hole now and the head has a fairly thin wall going round. Problem is, if I go further I guess I could damage the plastic ( a bit ) but even worse, that metal tab on the tank.

What would be my best option now? should I drill a bit more and hope the head comes off? advice is much appreciated.:|
 
#3 ·
Yes, I should have got a pic, but went back to it and the head came off after some prodding with a screwdriver. So, the panel then just popped off as that was the only screw.

NOW, my problem is what`s left in the hole, the threaded stem!! about 3-4mm sticking out, and it looks slightly off to one side, but only very slightly. I can`t twist it off with a pair of vice grips and there`s no space to cut a slot in the end.

What can I do now guys, really need some advice, thanks
 
#4 ·
***Update***

Resolved. Good fellas at Kawiship just about managed to break it free with Vice Grips. Was almost a no go, but was very lucky with only a few mm of shaft to grip onto (kkk).

Good'ol vice grips ey.
 
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