How To Remove Rounded Bolt?

jaysonD

jaysonD

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Trying to fit a blow off valve to my 2.0t! And wow they could have not put it in a worse place at such a worse angle. Had a right headache trying to get it off, managed to get two bolt out, but the top/ most awkward one ended up rounding off, I've spent about 4 hours trying to do this, mainly trying to get this once bolt out!
Anyone got any ideas for how to remove the bolt? Me and my old man have been trying to get it out using different siZe Alan key heads,torx head, flat head and clamps but it won't budge! Managed to get it out by 1/4 of a inch! I'm out of ideas n how to remove the bolt as I can't exactly drive it to the garage now!
 
Had a similar problem will a bleed nipple awhile back ,i ended up opening up a nut and tacking it on, with a welder.The heat helped freeing the nipple.
 
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Sounds daft but try tightening it back up slightly then undoing it again, that frees any crap in the thread and gets some heat into it.

Spray it with wd40/ac90 or ideally plusgas and leave it to soak overnight

Apply some heat with a blow torch

Weld a nut on as previously said

Cut it off and drill the bolt out and tap to a larger size or helicoil the current hole

Loads of options really mate
 
Feel like it's completely ******, I've tried wd40 it, can't get hammer in there can't get anything to weld or use a blow torch in there! Tried using them bolt removers but they just won't bite!
smurfworth said:
Sounds daft but try tightening it back up slightly then undoing it again, that frees any **** in the thread and gets some heat into it.

Spray it with wd40/ac90 or ideally plusgas and leave it to soak overnight

Apply some heat with a blow torch

Weld a nut on as previously said

Cut it off and drill the bolt out and tap to a larger size or helicoil the current hole

Loads of options really mate
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