Rounded off screw/bolt in plastic radiator removal

[sako243]

Any suggestions on how to remove this screw? The one lower middle of the picture. It's holding the fan shroud onto the back of the radiator. It's one of those coarse plastic but had a 10mm hex head on it.

It was very rusty and rounded off instantly. It's a little too small for my 10mm Irwin bolt extractor and too big for the next size down. Access isn't bad but not great and it's slightly recessed into the shroud so so far have failed to get any decent purchase with mole grips.

I've considered tacking a bolt onto it (would have to be a bolt so the earth can be clamped to it) but would prefer to explore all other options first because of the risk of melting the rad. I haven't looked but I don't think it'll be cheap and I know it's a sod to replace.

I need to get the shroud off so I can replace the alternator so it's got to come off. Last bloody bolt too and one of the easiest to gain access to.

 

[Onoff]

Cut a slot in it with a multi tool?

 

[DanZac]

Its a bit gash, but if it's only holding the shroud on, could you just drill the head off it and then just leave it missing when you put it back together?

 

[sako243]

Cut a slot in it with a multi tool?

I'd have to cut a blade down so as not to damage the shroud. Tricky but might be doable.

 

[sako243]

Its a bit gash, but if it's only holding the shroud on, could you just drill the head off it and then just leave it missing when you put it back together?

Considered, would need to pinch a R/A drill to get in the space though. Not the best photo but there's about enough space for two hands in there and that's about it.

 

[Onoff]

How about...degrease it. Slip a nut over and fill with Araldite?

 

[sako243]

How about...degrease it. Slip a nut over and fill with Araldite?

I like that idea! Given it's just into plastic that is a cracking idea.

 

[plewlandsbob]

Carbide burr and grind head off?
Knipex Twin grip , or engineer ( available from Amazon) brand screw removal pliers.

 

[sako243]

Carbide burr and grind head off?

Also considered but having done that to the tie rod from further afield I was hoping to avoid it with all the shards flying about 4" from my face.

Its up on axle stands and near the drivers front wheel so not much space to work.

 

[Onoff]

I like that idea! Given it's just into plastic that is a cracking idea.

Might need a ring of tape or silicone to stop the Araldite leaking out. I say Araldite but chemical metal etc.

 

[jimbo84]

Might need a ring of tape or silicone to stop the Araldite leaking out. I say Araldite but chemical metal etc.

A bit of milliput should do it and it won’t run out.

 

[Kram]

The multi tool suggestion, but instead of the oscillating type, use a rotary multi tool or die grinder with a 20mm diamond or resin wheel to cut the slot.

 

[m_c]

Cutting a slot in it, then trying a plain screwdriver is usually the first resort.

The issue is the screw is likely corroded into the plastic, and that they can often need quite a bit of torque to get them to start moving.
If a slot and screwdriver doesn't get it moving, then grinding the head off, and dealing with it with the shroud removed is usually the easier option.

 

[Redsailor]

Odd times I have managed to remove something like that by using a slim cold chisel. Place chisel on edge of head and tap it round and it may loosen sufficiently to get a pair of pliers on it.

 

[GRW]

Enough room to get a small impact screwdriver on it (not a full impact gun)? Wondering if one of those socket things for rounded-off heads (I'm sure there's a proper name, but can't think of it - I've got a set here somewhere) with some shock-loading from an impact driver might encourage it to wind out.

 

[sako243]

I've got a set of Irwin bolt removers but the smallest one is too small and the next size up is what finished off the bolt. It began to bite but not enough depth on the head to get a reliable purchase.

 

[Kram]

Another option if its in plastic, just heat it up with soldering iron and pliersnto pull it as the plastic lets go. Drill the hole for a brass insert.

I remember my dad having a real pain trying to remove a plastic sink nut with no access to grip it. Took me a few seconds to cut it off with a hot knife as we had a replacement anyway.

 

[hollow]

Knipex twin grips. Made for that job.

 

[Mark 5]

I've got a set of Irwin bolt removers but the smallest one is too small and the next size up is what finished off the bolt. It began to bite but not enough depth on the head to get a reliable purchase.

Ok twin grips would have been my first weapon of choice but you have tried that.

Plan B, apply some plus gas/penetration fluid then using a slightly larger size for the chewed bolt head, use an offset of flexible head ring spanner, get it seated on the head, at same time trap a piece of metal between the nut head and the inner ratchet so it grabs tight and gently turn.

Plan C, drill a hole in center of head, use an extractor or cut a slot into the head and remove that way.

 

[plewlandsbob]

9mm Six point socket , or 3/8 AF socket, which is approximately 9.5 mm. Grind down any tapered lead in , on inside of socket, to give maximum contact with bolt head.