stripped allen screw

XTINCT · Jul 4, 2019

This could come up on a Commando with allen head case screws.
I had an allen head case screw that had the allen head stripped out and it was recessed deep in the primary cover on a Bultaco. This bike had been stored in a shed with a dirt floor for 40 years. We soaked it in penetrating oil (PB Blaster), Then we cleaned it with acetone, put a little epoxy on the end of a cleaned allen wrench, let it set for a day, and it came right out. We made a tube by rolling up a piece of paper and set it down in the hole to prevent glue from contacting the cover.

lazyeye6 · Jul 4, 2019

Why not wait until this situation occurs on a Commando and then present it to this forum? This is not the Bultaco forum.

lazyeye6 · Jul 4, 2019

on re-reading the post, I can appreciate the suggestion.

jbruney · Jul 4, 2019

It is a really good plan & worthy of a spot in the memory banks because sooner or later.....

swooshdave · Jul 4, 2019

Epoxy like JB Weld or something else?

kommando · Jul 5, 2019

What I have done in this situation is to try using a metric allen key that is slightly larger and tapped it in and that can grip enough, Torx bits can also fit.

Bernhard · Jul 5, 2019

lazyeye6 said:
on re-reading the post, I can appreciate the suggestion.

But a useful bodge up to get you out of a hole, none the less.

cliffa · Jul 5, 2019

Bernhard said:
get you out of a hole.

Haha, I like it Bernhard

You can also dip the end of the hex key ( or screwdriver) in grease, then into sand, and it will really grip. I’ve done the same as XTINCT in the past with Araldite and sand mixed.

Cheers,

cliffa.

Yakatak · Jul 5, 2019

Coarse valve grinding compound

Tornado · Jul 5, 2019

I just went through this situation yesterday on my Bonneville while trying to renew rear brake pads. They are held in caliper via two special pins with an outside threaded 5mm hex socket head. This head sits flush to caliper body when done up. Whole caliper exposed to road detritus as it is underslung beneath swing arm.
First pin came out with my 5mm hex socket. Second did not and proceeded to round out. Tried all manner of fittings to tap in but none held. Even had some special diamond powder grit in a tube proported to work on stripped bolts and screws. No go. Went and bought an easy out type kit and drilled into the bad head until the tool could be tapped in enough to engage some metal. Out she came.

New special bolt should be ready to pick up today.

xbacksideslider · Jul 5, 2019

Thanks Xtinct

XTINCT · Jul 8, 2019

swooshdave said:
Epoxy like JB Weld or something else?

We used JB Weld.

lazyeye6 said:
Why not wait until this situation occurs on a Commando and then present it to this forum? This is not the Bultaco forum.

Having to re-read the post fits your moniker. LOL, no offence taken or intended.
I would also consider adding some very fine metal filings to the glue. Like you would get from a grinder.