Need advice, stripped bolts.

[surfish95747]

Hey guys, I am replacing the fork oil and dust seals and on the right fork the bottom leg bolt (6mm hex head) is stripped and the oil drain screw has been completely sheared off (previous owner).





When I insert the hex wrench into the bottom bolt, it feels like the hex catches a little so I know it's not completely smooth, but it is pretty close to being a complete circle.

Any advice on how to remove these two bolts so I can get some new ones in them? Thanks guys!

[LukeM]

Wow...that's pretty bad.  My condolences.

Your best bet _may_ be some sort of screw extractor.  Another option would be to use a Dremel tool with a very small bit, and cut some flat grooves in the screw, then pry it out with a screwdriver.

Alternatively, you could take the fork back to the previous owner, and insist that he remove it for you.   That probably won't happen, though.

Good luck.  I hope this helps.
Luke M

[Re-run]

Well, that sucks. The oil drain bolt isn't a big deal. Torque on those is usually pretty low.
The leg bolt can be harder but you have a lot to work with at least.

Get a set of left hand drill bits and extractors. Using left hand bits is best since the bit rotates the same direction that the bolt does to come out. The act of drilling it can potentially remove the bolt on its own, or loosen it a bit. Right hand bits can potentially drive the bolt in further.

They can be tough to find though.

Also, use high quality extractors. Cheap ones break and then are a real bitch to drill out.

[TOOLS1]

The drain screw should come out easy as Luke and Re-Run suggested, use a dremel to cut a slot in it, and use a screw driver. However you might get lucky, and be able to work it out with a pick. At worst, place a nut over it, and weld the nut to it through the hole, then turn it out with a wrench. On the lower fork bolt, I have came across several stripped bolts there. I always take a 3/8" drill bit, and drill the head off. Then after the fork is disassembled, I can turn it out with pliers. A tip on removing them is to always use an impact on them.
TOOLS