Fubar'd rotor bolt - creativity needed!

tom_fun

Hi there, I am replacing my 160mm front rotor disk for a 185mm but I have a problem. When I was removing the rotor bolts, one of them was too tight and when I was trying to unscrew it, the bolt has worn away on the inside so the allen key just turns and I cant undo the bolt

Any creative ideas out there to undo it? my best thought was to try and be a bit delicate with an angle grinder and try and wear down 2 sides of the bolt so i can get a pair of pliars on it

all help appreciated!

weeksy59

couple of options.

1. Knock a larger Torx into it,e.g next size up.
2. As above, then use an impact driver to get it freed up.
3. Get some plus-gas in there to help release it
4. using hack-saw cut a flat scredriver slot into it.

5. Last resort... get a drill out.

Chunkers1980

Are you sure it's an allen as opposed to a torx t25?

Your idea sounds good. Try and make some purchase on the bolt head. Undo all the other and see if a twist and wiggle of the disk works.

All else fails just whip the head off with a drill then move to an angle grinder - that can get maessy.

shm_uk

In the past, I have used a file to create flat spots on two opposing sides of the bolt head, thus enabling me to use a small spanner to undo the bolt.

shm_uk

Or use a hack-saw to cut a slot in the bolt head, then use a flat-head screwdriver to undo the bolt (you may need to use a pair of pliers on the screwdriver shaft to generate sufficient turning force).

chedabob

If you've got another set of allen keys, try them. I've got 3 sets and they're all slightly different sizes.

Try a thick elastic band too. Place that on the head and then use the allen key as normal.

Salsa

Try the screwdriver first, if that doesn't work just angle grind the bolt head off & remove the rotor, grab the rest of the bolt with pliers/mole grips & turn it out.

tom_fun

thanks for the ideas folks, used a grinder as in my original idea, did the trick in 2 mins.

panic over