unscrew a stripped allen screw? what tips do u have i was trying to take the head off to look at the cams and noticed that the allen screw is stripped! how the hell do you deal with something like this?

Well, you might be able to grip it by the head if you have a pair of vise-grips that'll fit, otherwise a tap-and-die set will run you $50 or so. Then order all new head screws while you're at it.[8D]

*EDIT* If you try the vise-grips method, make sure they really grip that puppy...

I have tried to file a nail (some hard material) to have a custom size allen wrench to fit that stripped allen head by some little hammering action.I succeed.
Good luck

Turk1 gives me another idea, you could *carefully* use a Dremel cut-off wheel to make a slot for a flat-head screwdriver, just don't go too deep![X(]

Make absolutely sure it is the screw head, and not the tool that is stripped. Quite often, on the smaller screws used on our engines, there is very little room for a sloppy or worn tool. I will usually try to grind the tip of the allen wrench off about 1/16 - 1/8" to get a good clean tip. Don't try to use a "ball end" driver. You can also sometime use a slightly larger wrench, maybe if it's metric, use the next larger SAE size, or vice versa, that you can force into the socket.

There is another way if the head is stripped out beyond hope after you've tried the other tricks. (Have you tried a tapered screw extractor in it - such as an EZ out?)

Select a drill bit that is slightly larger than the diameter of the shank of the bolt (But usually smaller than the diameter of the head) - a guideline for the drill size is a size or two up from the Allen key size - if you are using a 3mm allen key use a 3.5mm drill bit. Slowly and carefully drill down into the screw head until the head breaks off the screw - make sure that the drill is in line with the centre line of the screw.

Once the head comes off - you can usually take whatever it is that you are trying to remove off over the shaft of the screw and then you have something to grip on with a good set of pliers or vise grips to remove the broken one.

I actually have a few Left Handed drill bits in my collection (Yes they turn the other direction to normal) and these often work in such a case before the head gets drilled through.

Otherwise - Good luck with it - they can be a bit of a nuisance really.

I would use an easy out, tap it into whats left of the allen head. The use a small adjustable wrench on the end of the easy out (they are usually squared off) and unscrew the bolt. May take a couple of tries.

Final solution is above, grind it off and lift the head over the remain shank. Then use a pair of vice grips and crank it out.

Got to work at it.

Good luck.

Cheers,

Chip

I had a head of an engine I no longer needed given to someone who posts on RCU. Can't remember who. Maybe if they are reading this they could post how they removed to broken rocker cradle screw from a TT .91 FS head.

wow that was fast and good answers boy do i love rcu dont have to call up the hobby shops and worry id bother them bet they are slow due to the digital age!!!

From all of us to you, thanks for the compliment.

Do let us know how successful you were.

Cheers,

Chip

im going with the easy out drill bit sounds like the easiest way

Crazy: a word of caution. "Easy Outs", or screw extractors, are extremely hard metal. Which means they will break/shatter instead of bend/twist. You must apply pressure absolutely evenly, no sideways pressure for example, when using that Crescent wrench to turn the extractor. A better tool to use for turning it, is a tap handle. Taps have the same square shank and so a tap handle will work.

Working with these tiny screws and screw extractors, it is doubly important you go in straight, and apply pressure evenly.

I wouldn't use the ez-out first. It is the LAST thing I would try. If you break that sucker off your options suddenly get real limited.

I have carefully slotted the head with a dremel before. Do check you allen wrench to make sure it is not rounded, as suggested. If you don't know how to use an easy out or have never used one before, I would make that your last option.

I don't know how small of a screw he is talking about, but most of the screws we use are just too darn small for an easy out.