Stripped caliper bolt, hex head

[Edo]

Installing rear caliper on 2000 V11 Sport, apparently hex socket was not fully seated in head of bolt, so it spun in the hole. Banged the socket all the way in, but just spun. I have ez-outs about the right size, the short, stout variety. Should I give these a go or is there a better way?

[Fontain25]

In the past I have had success with a sharp punch and a hammer.

[wirespokes]

If you have any imperial allens, one of those might be a tight fit.

it might be possible to re-form the hex hole with a ball peen hammer - the rounded end. I've placed it against the allen and then tapped the hammer with a second one. Don't hit it too hard - wouldn't want to break the mount.

If you've got an impact driver, that just might do it. Familiar with those? It's like a chunk of steel rod with a way to attach a bit on the end. When you hit it, the bit wants to turn. A lot of times the combination of an impact force and the sudden jolt will loosen it up. Home Depot has them for seventeen bucks.

As a last resort, mix some metal filings in epoxy and glue a bolt or allen wrench in the hole.
 

[yogidozer]

If you have a torx bit, that you can gently tap in, that might help, the sharp edges will bit in.
But as wirespokes suggested, an allen wrench would be my first shot.

[fotoguzzi]

Is the bolt head in a recess or can you grab the outside of it with a vice grips?

[RinkRat II]

     Looks to me that a#5 EZ out with the very tip ground off would do the job. First try a Torx as was reccomended , I've had good succes either way .

      Paul B

[Edo]

The bolt head is in a recess. Tried to hammer on a new 6mm hex and the 6mm ez-out, hex hole getting rounder by the minute. My impact wrench doesn't have any hex tips, just phillips and straight slot tips.
I could ride over to a machine shop for help tomorrow
Maybe try to cut a slot in the head, but that is tricky because the heas is recessed.
I am still thinking.

[Green1000S]

Can you weld a nut on it? or weld the hex into it....

https://www.youtube.com/watch?v=aRrz-cphBY4 

[Kiwi Dave]

I've had success removing broken studs with a left hand drill set and a battery drill.

Might work here too.

[n3303j]

What about just drilling through the hex with a drill slightly larger than the body diameter of the screw? Head will pop off and you can slide the caliper off the remaining stud. Then remove the stud with pliers.

[Edo]

Yes, I thought about that as a last resort, but I guess I am almost there.
I may do that tomorrow.
Thanks.

[wirespokes]

I used to think the same about my impact driver till I realized the big black nose comes off. What's underneath is a 1/2" square to mount 1/2" bits. If you've got an allen for a 1/2" drive you're all set, otherwise a reducer for a 3/8" socket would do it.

It's quite likely a torx driver will break it loose. I've had good luck going that route too.

[tris]

Be careful with impact drivers and alloy castings unless they're substantial and/or well supported from behind

I managed to break a lug off my old Cali trying to persuade something free doing that!

[Huzo]

What about just drilling through the hex with a drill slightly larger than the body diameter of the screw? Head will pop off and you can slide the caliper off the remaining stud. Then remove the stud with pliers.

That’s the one.
You’ll have it off in 10 minutes..
Start by drilling with a size that just enters the hex.
Just make a dimple with that drill then replace it with an 1/8” pilot drill, gently working up to the bolt size as mentioned.
The first drill will make sure you’re in the centreline of the bolt.
Piece of piss, done it heaps of times. Allen bolts are good quality steel, but will drill nicely if you keep them sharp.

[Edo]

Done. Drilled through head to what I thought was deep enough, but still wasn't thru. Figured at this point that an ez-out would twist the head off. I'll be damned, the whole bolt came out.
I did have to use an electric drill.

Thanks guys 

[Darren Williams]

Done. Drilled through head to what I thought was deep enough, but still wasn't thru. Figured at this point that an ez-out would twist the head off. I'll be damned, the whole bolt came out.
I did have to use an electric drill.

Thanks guys