Originally Posted by
Peek the Geek
Thanks, dwood, for saving me some wasted time with the heat method. I'll give the carbide cutter a go tomorrow, but is there much danger of damaging the hex cavity enough that I will no longer be able to use a hex wrench to remove the bolt?
P the G,
I suspect that the broken piece of allen wrench is trapped in the socket head screw by a slight amount of burring near the top of the screw. If you use a carbide rotary burr carefully around just the top of the screw . . . there will be plenty of depth for an allen wrench to remove the bolt.
BTW, the suggestions for using heat would apply if you were trying to remove a stuck steel bolt from an aluminum part. But I don't think you'll need to resort to that. Just use a proper allen wrench.
Keep us posted with your progress!