In the process of removing my front end, I rounded off a caliper bolt. It's going to have to be replaced, but for now I need to remove it. Anyone have any tool suggestions? Grip pliers not seeming to work. I don't care about destroying the bolt...anymore than it is.

 

since the bolt is rounded, you can do either one of these...
1. dremel a line across the center of the bolt so that it's like a flat head screwdriver bolt and get it out that way or...
2. dremel opposite edges of the bolt until they are flat and then use vice grips.

i would do option 2.

 

Craftsman, Mac Tools, Mattco and Snap On all make sockets that you tap on with a hammer and they grip the head of the rounded off bolt. Then you use a ratchet to take them off. Much less chance of damage to the bike.

 

Screw extractor. You can get the drill bit/extractor combo for pretty cheap. First you drill a small hole in the bolt head. The extractor is tapered and reverse threaded, and you screw it counterclockwise into the hole you drilled. Once the extractor is deep enough into the hole it breaks the bolt loose. I've used them many times and they're a lifesaver, and very easy to use.

 

I'll try the extractor first. I think I have one around. Otherwise, I'll have to go to Lowe's.

 

For some reason I cannot get the extractor to grab. I think because it's hardened in some way. The extractor is a #2 and says to use a 7/64th drill bit. I couldn't find mine so I used a 1/8th, thinking that because it's smaller it should be better. I just have a hole in the bolt now.

Jimd2p, do you know what that tool is called?

 

Try to make the hole a littlr bigger you want the extractor to go in a good bit. Slightly bigger is better the smaller.

 

+1 on the sockets that tool suppliers use to extract rounded bolts, they work great. I would try that.

 

yeah, I doubt the screw extractor would work on that particular bolt. I second the sockets for stripped bolts. they do work well.

possibly might also use an impact wrench to break it loose

 

Lessons learned thus far:
1/8 is bigger than 7/64th
Screw extractors aren't meant to go into drills
Caliper bolts are tough as hell
No joy yet

I finally found my 7/64th titanium drill bit, still no joy. I can barely remove any material with it. It just spins like hell regardless of pressure applied, like it's smoothing the inside of that bolt.

I'll have to go to Lowe's tomorrow as the local hardware shop had every other size in a kit for the socket type remover except the friggin' 12mm.
Why in the world would a tool kit maker have 10mm, 11mm and then jump to 13mm in their kit?

OH BTWmods, please move this thread to General, as that is where it properly belongs.