best way to get frozen bolts out

[jimg1au]

apart from drilling what si the best way to get frozen allen key screws out po has stipped thr inside of head.also 3 flat blade bolts as well.
thanks
jim

[mick25]

I brought my self a bolt remover kit, you have to drill the right size hole through the bolt and screw the tool in, as you turn it, it tightens its self up and removes the bolt but i have broken one tool doing this it was a 6mm bolt i was trying to remove, larger bolts that you have to remove have a larger tools to suit and have less chance brakin .You could try spraying WD on it twice a day over a week that worked for me once, if it still has the head on the bolt and its been rounded off try fileing flat spots on both sides of it and use a spanner to remove. trying to heat it will heat the bolt and other part at the same time and may not work

[Marc.com]

remember once you break the bolt extractor you have a problem as they are hard like a tap, and like a tap the only way then is to bust them up with a bunch. Never use them myself as they tend to make matters worse.

bolt removal takes practice, or good tools, with Allen screws you have a problem as they are hard to drill, heat is usually a good start then move on to heat and CRC and finally drill them, the heat softens and loosens the bolt. Then you can often work em out with a punch or grind a bigger key into taper and drive it in.

BEST/CHEAPEST solution especially engine casings.....go to automotive machine shop and go 'here fix this'.

[oldfart]

If the head has snapped off , place a nut over it and mig or stick thru the threaded section . This will do 2 things ....allow heat  to travel down the bolt and lossen up and allow you to get a socket on it.
IT WORKS 

[lc4]

Option1:Without special tool
Use a small fine chisel and tap gently on edge of head of bolt / screw
Option 2: Special tool
Not sure were to source these but they are similar to a allen key (without the bend) and you drill down centre of bolt then tap the key into place and then use spanner to loosen.
Ezy outs are crap as they only put more pressure as they spread the bolt / stud and usually break making the task even more difficult.

[LWC82PE]

it helps if you use an impact driver well before the hex gets too rounded out. same goes for phillips head screws. Dont keep struggling with a screw driver or plain allen key and end up making things worse. while you still have a a bit of a hex or screw diver slot left attack it with a impact driver ( not its not the same thing as a rattle gun) and a couple good hard solid hits. if the head is beyond even a impact driver bit, then your in trouble and have to drill and use things like easy outs or as oldfart suggests, weld a nut onto it.

[pokey]

Drill out the centre of the bolt all the way thru just leaving the thread.

Grab a hacksaw blade and grind off the back of the blade just leaving the teeth and minimal backing.
 insert modified blade into modified bolt now with hole and push and pull, cutting thru the thread of the remaining bolt.
 find a centre punch and tap out the remaining thread from the bolt hole and it will come out easy.

[Tim754]

 Marc got it covered    "BEST/CHEAPEST solution especially engine casings.....go to automotive machine shop and go 'here fix this'."   Trouble is bastards keep wheeling insanity inducing agony around to me................. and I dont have a machine shop...........

[holeshot buddy]

forget everything everyone said except oldfart
if the bolt is in aluminium
place nut centrally over bolt
and mig weld through centre
let it cool a few minutes then undo
if the nut doesnt take properly
just re do it
pease of piss

[GMC]

Have to agree with Oldfart & holeshot too. This works best so long as you can get to the bolt to be able to weld to it & it's not completely frozen in.

Easy outs are next to useless, ecspecially on small bolts which is mostly what we deal with in bikes. Also total waste of time if the bolt is frozen in.

If the bolt is frozen in then you will have to drill. This can be tricky in alloy as the drill will find it's way into the softer alloy. Best to start with a new small drill bit & work your way up in size. I prefer "shorty" No. 30 or No. 20 drill bits for pilot holes. Because they are shorter they flex less & are easier to "aim"

[matcho mick]

another neat trick is l/h drill bits,9 outa 10 times the bit grips,spins the stud/bolt out,neat too is the drill bits heating as it does it's thing,