993tt

Apologize for the cross posting but since there's no forum for tech questions and I'm panicking...


I got big problems with a allen screw... After two hours of trying to loosen one I finally applied too much force and the inside went round

I'm planning to weld an allen key onto the bolt tomorrow and try to get it loose. Not my favourite choice because it's on the engine head but I don't know what else to do... As usual (in a 911) it's very tight and I can't use any kind of wrench and I don't want to rip out the engine.

Is there anyone with a better solution. Any help is VERY much appreciated.


/E

Sean79 5spd

You could try drilling the head and then using an easyout

Rez

I'd put some penetrating lube on there now and give some time to soak in. Then, I'd pound in a larger size allen, metric - 1 size bigger some times work, but also consider a standard allen, as sometimes they fall sizewise in between the striped allen size and the next size metric.

Good luck.

Lizard928

drill sideways through the head of the bolt and drive a screwdriver through the hole and turn it that way.

993tt

No room for that I'm afraid...

/E

Randy V

A variation on Lizard's suggestion - use a Dremel tool with a cutting disc to cut a slot across the bolt head for application of a large slotted screwdriver.

Apply a penetrating oil first - something like PB Blaster. WD40, while commonly used, is not an effective penetrating oil.

993tt

Thought about it and saving it for my last cance...

/E

993tt

Now that's what I call creative thinking! Why didn't I think about that?

Thanks!

/E

ViribusUnits

Or JB weld the allen wrench to the bolt.

JB is pretty dang strong, and won't dammage anything.

tresamore

If you use Lizards and Randy's suggestion and it still won't budge, try using an impact screwdriver in the slot. There have been times I've used the slot method and the bolt needs a quick jarring to loosen up. Be careful, too many impact hits can break the bolt head. Best of Luck. Let us know how (and if) it "turns" out.

993tt

hmmm... what's JB?

/E

993tt

Tried the impact but I don't want to abuse it too much since I don't know how solid the aluminum where it sits are. Don't want a crack in the head.

/E

Gretch

I used this technique a week ago on cap head allen bolts on my 928 engine. The key is to use a drill (if you can get one in there, I used one with a 90 degree chuck) bit that is just slightly bigger than the rounded off hole in the head. Then take the appropriate easy out and tap it into the hole with the side of a ballpene hammer. twist out with what ever you can use to get ahold of the end of the easy out.

Important thing to remember the tension on a bolt is all applied to the underside surface of the bolt head where it comes in contact with the material being bolted down. If you relieve that tension (without breaking the head completely off) the bolt will remove with minimal effort.

To translate this into usable information, if you can get a drill into the cap head bolt anf the easy out method does not inititially work, drill a little bit deaper into the cap head. Do so in small increments. At some point the tension on the cap head will be significant enough to strech the remaining material in the bolt head and it will turn out quite easily. The key is to reach this point without drilling the head completely off.

If that does happen, use a smaller drill and a smaller easy out in what is left of the bolt and it should remove quite easily.

Ask me how I know.......

Garth S

"Real" penetrating oils can only help here. Aerokroil (Cano Labs) is excellent. Also, a Wurth sales rep passed me an aerosol can of "ROST OFF" - i haven't yet tried it, but it's principle of operation is to 'deep freeze' the bolt/ etc. to shock it into release and to allow its penetrating oils to adsorbe. May help, for it sounds like there's little room to play.

heinrich

can you vise grip it from the outside?