Stripped Hex Head
 

I've got myself in a bit of a mess and it's a little out of my wheelhouse.

While trying to remove one of the 2 clamping bolts on the NDS of my Ultegra crank arm I stripped the head. They were properly torqued when I last reassembled the bike. That was about 7 months ago. Well, the hex head is stripped, I've tried a larger sized hex wrench but I'm getting nowhere. I currently have it soaking in PB Blaster. How do I get this damn thing out?

sometimes a Torx bit can be pounded into the stripped allen socket...

i've used Valve Lapping Compound in partially stripped allen sockets to ADD TRACTION to the bits/wrenches' tips... It Works... (Hot Rod Magazine "tips" to make Philips screws easier to remove, 1968 or so)...
What does the Tip of your allen wrench look like? is it rounded off on the working edges? might be time for a new one... i wear out 5mm wrenches frequently... tend to re-dress them a few times on the bench grinder, making sure to Cool the tips frequently while doing so... ;)

There are Broken Screw/Bolt Extractors.. common name: Easy Outs... any auto parts outlet will have a set... the new short cone types might work without pre-drilling...

and then.. there's the last resort... A Drill... the problem with doing that is the nut will lose grip and begin spinning in the crank arm...
i start with a 1/4" bit, then go with a 5/16" next... then use an appropriate size pin punch to remove the remainder...

i tear down a lot of old rust bucket bikes...

I did buy an easy-out and it totally stripped the head to nothing. I ending up cutting the bolt between the slot in order to get it off. Now I have the threaded part still stuck in the arm. I'm just buying a new arm.

Try using a dental pick type of thing to turn the broken part. Try turning it in the normal direction to remove it but from the backside of the hole. Trying to spin it the other direction may cause the cut end to get stuck in the threads or you could just try drilling the broken end also from the backside and it may catch on the bolt and spin it out.

Find the nearest size torx wrench that won't fit. Grind the end square, producing sharp corners, being careful not to let it get hot.

Now, tap it into the bolt head, where it will cut its own path, converting the bolt to torx. Do this to full depth before trying to loosen the bolt, then use this tool or a fresh one of that size to turn the bolt.

Some guys shouldn't go near tools (and not just in NJ)...

Late to the game, sometimes a little heat can aid.

I believe as the install goes, reverse, the removal needs to go back and forth on the bolts. If you only did one bolt fully it could have left the second bolt awkwardly tight.

Where you are now, try some heat, try drilling from the back, that may push it out. Should be not difficult now that it’s not on the bike. I’ve drilled a hole a bolt epoxied in another for removal.

Nothing to lose if you are set on buying another.

Seems maybe you weren’t



Taking your time.

.

That's a great trick!

And some people should stay off social media.

that's some HAMB / Garage Journal chit rait chere