Bolt stuck and rounded

R

Rodd

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Jan 22, 2008
150
Pearson 424 East Hampton,NY
3rd of 3 starter bolts is stuck. I have soaked it in PB blaster, but it wont budge- also, i seem to have rounded one of the corners of the bolt so that a box wrench keeps slipping. Any suggestions? I know they make a tool that will crack the head of the bolt off. Access is extremely tight-- I could not get a socket on, as I was able to on the top two starter bolts. I was thinking of trying to get a vise grip[ on it, but i doubt I would be able to turn it even if I can get the plyers onto the bolt head.

All ideas welcome-- this is a real pain!!

Rodd
 
Allan12210

Allan12210

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Jan 22, 2008
1,666
Hunter 34 Alameda CA
Don't recommend you break the head off yet. Instead, get a bolt extractor socket like this one:

http://www.mutualscrew.com/product/...K_-SdidPHH4onzQK9ng9MGRZrI13VEV0nKxoCXorw_wcB

They sell them at Walmart and other places. You should find a source pretty easily by Googling bolt extractor socket.

It will put the force on the faces of the bolt head instead of the corners like your wrench does. If you have room for the wrench, then I hope you can find room for a ratchet handle or breaker bar. An extension could move you out into an area with more swing.

Just checked....they have an entire set in Metric and English (SAE) at Harbor Freight.
 
JoeWhite

JoeWhite

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Mar 6, 2008
1,343
Catalina 1999 C36 MKII #1787 Coyote Point Marina, CA.
I would use Dremel with multiple disks. It will wear out or break before it is cut off.
 
Allan12210

Allan12210

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Jan 22, 2008
1,666
Hunter 34 Alameda CA
Joe and Stu, I guess I am missing something in your suggestions. Where are you using the Dremel? I've used the cut off wheel to cut a slot in a bolt head so I could turn it with a flat bladed screwdriver. But I needed plenty of access for the Dremel. I've also heard of grinding between the head of a bolt and its mating surface to relieve the pressure of over torquing and rusting. The obective was not to cut the head off but to lessen the force required to unscrew it. Again a lot of access is needed. I think in this case one wouldn't want to leave a stud in the block (by removing the bolt head) because that would be really hard to drill out or extract. We're not talking about splitting a nut, right?
 
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Apex

Apex

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Jun 19, 2013
1,212
C&C 30 Elk Rapids
PB BLaster is the first go to, sometimes patience and time with said solvent. Next up would be shock force, hitting it to help break free. Have you tried heat? Your lack of access is really a pain and extra challenge. Cutting off the head, removing the starter MAY yield you the stud to grip, does that improve access to that bolt though? If not, that last ditch effort may put you in more of a bind.

G/L! stay patient, tap-spray-wait, spray-tap-wait. Some have soaked for several days. The impact extractor looks to be a great solution to your rounded edges.
 
R

Rodd

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Jan 22, 2008
150
Pearson 424 East Hampton,NY
Thanks for all suggestions!
I have been reading about the bolt extractors. That is what I will try next. I hope they are not too deep, so that I can fit one onto the existing bolt head in the tight space I am working with. I should then be able to get an open end wrench on and hopefully remove! I have been soaking with PB Blaster each time I visit.
Stu: yes I have a dremel, but prefer to try the bolt extractor first.
I also watched a video where a mechanic uses a chisel and hammer to first put a groove in the bolt head, then hammers on an angle to get the bolt to turn. Anybody tried this method?
 
Maine Sail

Maine Sail

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Feb 6, 1998
11,709
Canadian Sailcraft 36T Casco Bay, ME
Couple of suggestions..

6 point wrenches & sockets!

Articulating socket knuckles, extensions & impact drivers

Now that it is rounded it just becomes a time vs space project. Try, try, try to get a 6 pt socket in there now before you round it any more. You would be amazed at what a knuckle or two and extensions, especially wobble heads, can do...

For future reference use 6pt on anything you even slightly suspect may come out hard....
 
njlarry

njlarry

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Sep 23, 2009
1,475
O'Day 34-At Last Rock Hall, Md
I have removed rusted lug nuts from a trailer using a propane torch. The week before a tire place broke three lugs using an impact wrench on the opposite wheel.
You may not have enough room to use a propane torch but I have often wondered if a soldering iron could supply enough heat to break the rust? You might try it along with an extractor perhaps used with a cordless impact drill. Luckily you have the off season to take your time.
 
Roland5048

Roland5048

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May 12, 2004
1,505
Hunter Cherubini 30 New Port Richey
It's always the last bolt, nut, screw, etc. that gives the trouble. The trick is to start with the last one first.
Roland
s/v Fraulein II
 
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B

Benny17441

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May 24, 2004
7,173
CC 30 South Florida
By cutting of the head of the third bolt you will be able to remove the starter and then you will have some room to work the bolt out. You could also....., impact can break a bolt loose, if you can grab it with pressure plyers you would not need to be able to turn it much, just give it a couple of repeated whacks with a hammer to see if it breaks. Another way, can you squeeze a chisel in there and have room to swing a hammer away from the starter? Time for finesse mechanics is over, its time for cutting and hammering; do plan your move and use patience when applying breaking force.
 
Apex

Apex

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Jun 19, 2013
1,212
C&C 30 Elk Rapids
Good point Benny: When trying to break free, be aware of what is directly behind should the wrench slip off, of or break free suddenly. My oil pressure sensor for example could be sheered off.
 
Rich Stidger

Rich Stidger

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Feb 10, 2004
4,137
Hunter 40.5 Warwick, RI
I have had the best luck (after PB Blaster) with a 6-point socket and an electric impact tool. On smaller bolts/nuts, a battery-powered impact driver also works well. The key is the impact force. It will break the fastener free without snapping it or rounding it any further. Be sure to re-assemble with Never-Seize.
 
W

wufibugs

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Aug 16, 2009
1,000
Hunter 1986 H31 California Yacht Marina, Chula Vista, CA
The impact driver is a very good suggestion. However, if the head is rounded beyond using a socket, you might try the largest pipe wrench that will fit in the available space.
 
R

Rodd

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Jan 22, 2008
150
Pearson 424 East Hampton,NY
SUCCESS !
Thanks all for the many good suggestions ! I wound up taking a file and straightening two of the rounded corners that I could reach. After that I used a 6 point socket and got a decent angle with a long extension bar. Bolt was really frozen in there. Had to turn about half way out until bolt would turn without a wrench.

I noticed that the starter I removed, a delco remy has a hole in the casing surrounding the pinion gear. A replacement starter I have does not have that hole. Does it make a difference? (this wrenching is fun !!).
 
Allan12210

Allan12210

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Jan 22, 2008
1,666
Hunter 34 Alameda CA
Rodd said:
SUCCESS !
Thanks all for the many good suggestions ! I wound up taking a file and straightening two of the rounded corners that I could reach. After that I used a 6 point socket and got a decent angle with a long extension bar. Bolt was really frozen in there. Had to turn about half way out until bolt would turn without a wrench.

I noticed that the starter I removed, a delco remy has a hole in the casing surrounding the pinion gear. A replacement starter I have does not have that hole. Does it make a difference? (this wrenching is fun !!).
Click to expand
Excellent! Don't forget the anti seize on reassembly. Maybe move one of the better bolts to that position unless they are all different sizes.
 
D

dlochner

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Jan 11, 2014
12,959
Sabre 362 113 Fair Haven, NY
Allan12210 said:
Excellent! Don't forget the anti seize on reassembly. Maybe move one of the better bolts to that position unless they are all different sizes.
Click to expand
Bolts are cheap, replace them all. And don't forget the anti-seize!
 
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