Hex bolt removal

[MarkT]

Hi when I fitted my replacement intake manifold rubbers the hex bolts holding them on were done up so tight!!! I managed to get them all out apart from one. I was using a hex socket on 3/8 rachet and one just rounded off so I could not replace no 2 intake.

I do not know if it is leaking as apart from tickover everything is great. I would really like to replace it. That nice mr EC adviced to drill the top off the bolt so I would just have a stud that should come out easy. I do not have power in my garage so would have to use a cordless drill that does not last that long.

Extractors would just snap off it's so tight but I just wondered if anyone had any other ideas or a good bit for my drill bit that would easy take the bolt head off.
Thanks

[Hogdigerdy Dog]

have you tried Plus Gas you can get it from most motor factors, it's a releasing agent for stuck/rusted bolts etc and is sh*t hot, get the one in the can and not the aerosol it's much better
apply round the bolt head and it will penetrate down the threads, i'd leave it a good few hrs or even over night,
if your hex head is rounded then go up to the next size bit and gently tap it in, hard enough to seat but not hard enough to bust anything and it should come out

if not as ec said cut the top of and once you remove the boot you'll be left with about 8/10mm of stud sticking up, but if this snaps off you'll need to get it drilled out and either re-tapped if your lucky or helicoiled which is a right pain

[Taggyd]

can you get at it to cut a slot in it with a junior hacksaw or dremel type thing, then get a screw driver into it?

[Evilchicken0]

Borrow a 35m extension cable and run it from the house ???

http://www.ebay.co.uk/itm/Extension-Ree ... 6b1b9b553f

[MarkT]

Thanks for replies no you can't cut it with hacksaw and I would need 100 meters of cable to get to garage! I did think about buying a cheap chisel and trying to make two slots opposite each other. Then use a hammer screwdriver to get it out and chuck the chisel! I just come in from a ride soaking wet and the bike ran great apart from idle and low speed so I think it is not leaking. I just hate the fact that I know it's there and also the new inlets grab the carbs much tighter! It was a he'll of a job to push carbs in so they are a better fitting. Would just like them all to be done!
Thanks again

[Taggyd]

get a plank about 6ft long. Ride the bike up it, into the house and work in comfort!
problem solved!

[kaighn80]

torx bits are the answer in this case, you'll need to hammer it in but once its into the metal of the bolt it will bite really hard and if your careful and only apply a turning motion on the ratchet or breaker bar whilst keeping it perfectly straight it will come out.

[MarkT]

Thanks, Mrs ain't keen on the plank idea lol but might give the torx bits a go!

[Evilchicken0]

Can't you get the bike any closer to the house ???

Alternatively dismantle the house and rebuild it closer to the garage

[hunter]

Easey solution here,strip the bike to bits,the carry all the bits up to the house,
Rebuild bike, bemove bolt fit new stub,test engine if satisfied strip down bike, take back from house rebuild bike take for test ride