Rounded Torx - Need Help

I was taking off my Tonneau in prep for getting a shell this weekend, and I can't seem to get 2 of the bolts out. 2 of the TORX heads are totally rounded out and they are torqued REALLY tight. I've tried turning it with vice grips, but it won't budge. Not sure whether to try drilling it out, cutting a slot. I'm freaking out a bit. Any suggestions or help welcome. Located in Novato.

 

Weld a nut on it. Let it cool about 5 minutes on so and back it out.

 

I would love to do that if I had welding equipment, sadly I dont. .... Other options?

 

Looks like that used to be an alan, not torx

Looks like I could get it with a set of vice grips, but if you can’t, yes, slotting it should work

 

got an angle grinder and a cutting disc? Easy to slot it

 

Take a cutoff wheel and cut a slot and use a screwdriver.

 

Easy, weld a nut as some mentioned or slot it with a cut off wheel

 

Thank you all!!!

Slotting it worked perfectly, once I found a bit enough screwdriver blade and turned the shaft with a crescent wrench.

Now I just gotta go find some replacement bolts.

Thanks again for the tip.

 

Fastenal

McMaster-Carr

Local hardware stores

 

Take the remainder to make sure you get the proper size but I'd just go to Home Depot or Lowe's. If you have a Grainger or something like it, you might be able to get coated parts.

 

Just to be safe, run a thread tap to clean out the threads and apply some anti-seize to the bolts so you don't have same problem next time.

 

Doesn’t anyone use Easy-outs anymore?

 

Unless there's a real need, no. Why? Because at the point you need some kind of extractor, you're also likely going to need some kind of repair kit--if you can avoid repairing threads, you're better off.

 

sounds like you got it handled, I've some sockets that you drive down over the head that you can use a socket to extract the bolt. id grab a standard head bolt this time unless you like the recessed head.

 

Have you ever used them? They are an extractor! I’ve used them on hex heads successfully. Drill using a smaller bit that won’t damage the threads and use the easy out to extract.

 

Yes, I have--several different kinds. I've welded bolts on, used knipex pliers. I'll stick with it's easier to slot than drill when you can.