My knuckles are raw!!! HELP

[rapidtornado]

Made the absolute school boy error today used a size35 torx bit instead of a size 40 by mistake, wondered why the bolt wasn't giving purchase and yes you guessed it rounded the begger!!!

And of course is in a real tight spot (EFI inlet manifold bolt under the throttle body) any suggestion before I put my hammer through the front wing?


Matt

[gingea1pom]

Matt,

Knee jerk answer could you weld a bolt onto the rounded torx bolt.

Tell me I am not talking out of my ar**

Cheers Ginge

[rapidtornado]

can't get the head of the welder in there

[rapidtornado]

Just when you think you are getting somewhere..... managed to drill out the centre of the bolt wedged a size 35 torx into the hole, about 5 mm deep, put the wrench on, good purchase.... happy days no ping! torx bit has snapped off in the centre of the bolt, now I got a hardened bit wedged in an already rounded out slot, I think it's fubar'd

time to sit and think!!!!!

[Johnnybizzle]

Bugger,

Time to carefully drill out and re thread i think, my engine has half dozen different threads where over the years a few people has tinkered with it.

[rapidtornado]

My friends the beer is flowing tonight!!!

After 5 1/2 hours of attacking this fricken bolt I managed to get a slot through the middle, butcher up one of my old wood chisels, file two flats on the handle then carefully unscrew the bolt, this sounds a bit basic but it took 1 hour of hacksawing just to get the slot in it due to access

My car will now officially be called 'the bolt'!!! the fun bit starts now working on a new EFI plenum design to bolt back up to the car

Happy days!!!

rapid

[gingea1pom]

Well done that man

[Headshot]

Been there with plumbing before, every time your hacksaw slips off you feel like lying on the floor and crying

[Hoybi]

if you can reach it, grind a slot with a Dremel kind of tool, so you can use a scredriver