Help … knackered button head hex bolt!

[DaveH]

The battery on my Africa Twin is cunningly hidden behind a tiny plastic toolbox that is held on the bike by a metal bracket and some deeply recessed button head hex bolts that are made of cheese.

Sadly I’ve rounded one of them off and managed to break an extractor trying to get it out. The broken end of the extractor is now firmly stuck in the bolt head.

What next? Any suggestions? Anyone got the necessary tools and skills to help me out?

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[billinom8s]

Ihave drills and easy outs here

[Jug]

It's a shame you went in with an extractor as my first try would be to hammer in an over sized torx bit and try again.
Right now I would use a mini grinding disk (like on a Dremel) and put slot across it and then use a manual impact driver to shock it out.

If that failed I might try to grind some flats on two sides and then get a small open spanner on it, but that would damage the bracket.
Could also try to grind the head of that bolt away, and with it the remains of that extractor, but that still leaves the thread stuck in there and also might damage the bracket.

Next option could be to weld a small nut on it and then it could be unscrewed with a socket, but then the heat would likely damage the plastic box so I think I'd just resort to grinding. First just a slot and if that fails remove the bolt head and worry about the rest of the thread afterwards.

[Jug]

Just another thought, can you remove the other screws from that bracket and then bend it outwards a little to remove the tool box. If so you could then try using the bracket to turn that bolt, it might be enough to loosen it.

[Robbo87]

Hmm . . . . . Is there room to dremel two flats on opposite sides of the screw head and then get an open ended spanner (or, in extremise, a good set of mole grips) at it?
Or, grind off the whole screw head (broke screw extractor and all), then drill out . . . . and rethread to one size bigger i.e. M5 to M6.
Or, ---------- // ------------------- ------------- // --------------- ---- // ------ . . . . to whatever size needed to accommodate a through bolt and backnut.
Or, ---------- // ------------------- ------------- // ----------------- ----- // ------- . . . . and fit a M4, M5 or M6 'Rivnut' - I have these, they're a godsend in situations like this. If you want to go down this route, I can do that at mine for you.

[DaveH]

Thanks for your suggestions everyone.

Clearly I should’ve gone with the oversize torx bit first, so I’m going to see if I can get the broken extractor out and try that.

If that doesn’t work then I’ll be back and gladly take the kind offers of help

Wish me luck!!

[billinom8s]

just wondering why you were using a drill to work the extractor bit?

[Mervin]

A centre punch and try and tap it around may work

[Ruffian]

Bugger.

Bin those easy outs. They cause more harm than good.
As jug said, torx has much more effective.

I would try and tap the easy out to release.
Then go with hot air gun for warmth to help.

Would go hammer impact driver and torx if possible .
If that doesn't release it.

Then would fire up the welder.

[Bilko1000]

Hi I have a tool that might remove that I used to remove a similar bolt but Im based in Plymouth

[DaveH]

just wondering why you were using a drill to work the extractor bit?

It’s a drill driver … that’s what the instructions said to use.

[DaveH]

A centre punch and try and tap it around may work

Sadly i don’t think there is the space for that approach

[DaveH]

Bugger.

Bin those easy outs. They cause more harm than good.
As jug said, torx has much more effective.

I would try and tap the easy out to release.
Then go with hot air gun for warmth to help.

Would go hammer impact driver and torx if possible .
If that doesn't release it.

Then would fire up the welder.

I’ll give it a go

[DaveH]

Hi I have a tool that might remove that I used to remove a similar bolt but Im based in Plymouth

Thanks … I’ll bear it in mind

[DaveH]

Managed to get the extractor head out of the bolt, but can’t get a torx to bite so I’ve ordered a set of punches and a small hammer from Amazon. If that fails then it’ll be a Dremmel next!