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  1. #1
    Senior Moment Member Gee3's Avatar
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    How to remove a stripped allen bolt on the downtube...

    Or... The Dremel is my Friend!!

    I had asked how to remove the stripped bolts on my downtube some time ago and got several helpful answers. The OE bolts were way over-tightened from the factory!

    I first tried the screw extractor but the set I got did not work. They were the spiral type and although I followed the instructions to drill the hole larger and use the extractor it still wouldn't grip and I couldn't get them out. I thought about the other type of screw extractors but since these weren't successful I wanted to try something else. At least try one more thing to keep me from admitting defeat and bringing it to my LBS! (and with it being a round head I was not able to use my vise-grips)

    So after searching my storage for my Dremel at the in-laws I finally found my last hope.

    I then went to Home Depot and bought a set of grinding discs that were made to cut metal. I bought a bunch just in case.

    After taping up and protecting the area around the stripped bolt heads I went to work.

    It only took a little bit of Dremel work to notch the bolt heads to accept a flat head screw driver. But after doing so I was able, with a little bit of force, to turn the over-tightened bolt head and remove the offending bolts!

    So with help from everyone on the board and a little patience I was able to remove both bolts in only about 10mins. Hopefully this post will help others with similar bone-headed moments like mine!

    Thanks again!


    Tools of the trade...


    Taped off area


    Dremel to the rescue


    Bolt notched and ready


    A little bit of resistance but it finally came loose


    The offending part


    All done! (a little blurry, but the bottle cage is now in place!)
    This day will be over... one of these days!

    "I have cancer, cancer doesn't have me."
    Quote from a Kaiser commercial that reminds me of my mom.

  2. #2
    Elitist Troglodyte DMF's Avatar
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    Good one! I put a link to this thread in the Hints and tricks sticky.
    Stupidity got us into this mess - why can't it get us out?

    - Will Rogers

  3. #3
    rebmeM roineS JanMM's Avatar
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    Love a happy ending to a story.

  4. #4
    Senior Moment Member Gee3's Avatar
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    Quote Originally Posted by JanMM View Post
    Love a happy ending to a story.
    Me too! Especially since this is a new bike!
    This day will be over... one of these days!

    "I have cancer, cancer doesn't have me."
    Quote from a Kaiser commercial that reminds me of my mom.

  5. #5
    Mo No steelblue's Avatar
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    G, good job. You can actually re-use those screws.

  6. #6
    Infidel oldfool's Avatar
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    I predict that you will find many more uses for that cutting wheel. When my wife gave me my current Dremel I told her thanks I didn't need another one ( I already had two. One of which dates back to the early days of plastics). Turns out I only didn't need the storage case as the tool is always on the bench and plugged in with either a cutting wheel or a wire brush in it. By the way its a great tool for removing rivets or trimming machine screws that are too long. Good job.
    Oldfool
    tinkerer, maker
    Aviator, retired - Mariner, retired
    www.oldfool.org
    ----------------------------------------------------------------------------------------------------------------------

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