So as i'm trying to remove my intercooler to make motor mount removal easier and to replace the hvac fan duct.

The center allen bolt is stripped like no other. Basically a complete circle, with no way to get it out.

What is the best way to get this thing out? Drill it?

Big pain in the ***.

Somebody give me an idea.

I hate allen bolts.

Thanks.

 

The center bolt is the worst one that could happen to. No real vice grip access to the head. Allen bolts are HARD. Drilling will be a real pita. An easy-out may work, but you'll probably end up drilling off the entire head.

I might try cutting a slot for a flat blade screwdriver with my dremel and a diamond saw blade I have.

Have a mig welder? Could weld something to the head and grab that with vice grips. I've seen that work on other fasteners.

Good luck.

 

Try a easy out stud remover, they thread in the center in the opposite direction so that while it's tightening in the hole, it's loosening the bolt. Sears has them for a reasonable price.

 

An easy out will work, but access might be an issue. I once had a similar thing happen while working on an engine, basically chissled a notch in the head big enough to get a larger implement within, then cross fingers.
GL

 

just did this last fall - the reverse thread thing works great. just lightly hammer (lightly tap not go mongo on it) it into place and it will turn right out. make sure you have the new bolt (it came from Germany when I needed one) before you do this but in a pinch, once you get it out, you can cut a nice slot in the head with a cutoff wheel and use a big screwdriver to install and remove

 

Drill the head off the bolt -- remove the IC then grip it out.

 

I like the way Chris thinks. After years of working on aircraft, thats what we would do.".Keep it simple stupid " is our saying....

 

best part about stripped allen bolts (SHCS) is that there is a built-in pilot for drilling -- and they generally are quite soft.

 

I might take the easy out route first, and if that doesn't work, I'll just drill it all out.

Thanks gents.

 

definitely use a bolt extractor before drilling anything...truly lifesavers

 

Only thing I fear about easy-outs is once you break it off in the bolt, its really hard to drill out.

 

for those curious, here is how I intend to deal with this.

I'm going to dremel a slot into this screw, and use a 3/8" screwdriver socket to hopefully loosen the bolt.

 

I gently used an ultra sharp chisel to make two slots for a big flat head screwdriver.
It came right out and then I cleaned it up and just re-used it.

 

same idea here.

that said, reusing it is just crazy talk.

 

ok guys wanted to give you a resolution here.

Given how recessed that bolt is, slotting it was not effective.

So, I powered up the old cordless drill and the biggest bit I had and went to town.

Took about 35 minutes, but pop she goes and out comes the IC. At that point, I unscrewed the remaining piece of the bolt by hand.

Put a new one in with some anti-seize, and we should be all set.

alls well that ends well.

oh, and I want to punch porsche engineers who thought of those rear hood shocks in the *********.