removing a bolt with a rounded off head
 

So I get my engine back from the machine shop where I had him put in the pistons/rods/rings and I start the rest of the assembly. As I'm putting on the water pump I try to give the tensioner pulley a spin....SEIZED! But not just seized, whoever put it on last time decided to torque the bolt down to about 50000000000 ft/lbs then round the head off. I've had it soaking in PB blaster for two days and it still won't budge. The 14 mm socket just slides right off if I use any force, so I went to the trusty old vice grip, again, slid right off. Anyone have any ideas on how I can get this fucker out?

Re: removing a bolt with a rounded off head
 

I have in the past cut the heads of rounded bolts to accept a screw driver and got them out ... used a dremel. But I am doubtful that will work with this being torqued as much as it prolly is ...

I have a socket called a "gator-grip" I think. And it is supposed to grip any bolt head ... so I have in the past used the dremel to reshape the bolt head to resemble a bolt head ... and then slapped that thing on there ... it works sometimes ..

I think they make sockets that are to be driven onto the damaged bolt head with a hammer and used to remove it ...

Re: removing a bolt with a rounded off head
 

if nothing else works, tac weld a socket on it then buy a new bolt, i've had to do that a couple times, i did a full bead though since a new socket and bolt would be $10 max for most, not like you'd probably be able to use the socket again anyway

Re: removing a bolt with a rounded off head
 

yep. My last idea was welding a socket onto the bolt. But I was hoping that would be my last idea. :(

Re: removing a bolt with a rounded off head
 

That sucks. Mine on my SE teg was like that almost. I barely got it off w/o stripping it. People going He-Man on timing belt related bolts sucks hardcore. It took two days just to get the timing belt off of that car and like less than a few hrs to put it back on....

Re: removing a bolt with a rounded off head
 

Weld a socket on and call it a day.

Re: removing a bolt with a rounded off head
 

If you cant get it off with vice grips, be ashamed.

Re: removing a bolt with a rounded off head
 

I suceeded many times with this problem using the SQUARE easy out. Drill the proper size hole, wedge the tool in with a hammer then the bolt should back out. If not the welder will come in handy.
http://www.sears.com/sr/javasr/produ...id=00952315000

Re: removing a bolt with a rounded off head
 

this worked for me on my shift stabalizer bolt...

http://www.sears.com/sr/javasr/produ...id=00952160000

Re: removing a bolt with a rounded off head
 

I think Im a tool junkie :S