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How to remove rounded Allen head bolts | remove rounded hex key bolts 8 different ways

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How to remove rounded Allen head bolts | remove rounded hex key bolts 8 different ways

4,186,386 views October 25, 2018 13:47

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ChannelUltimate Handyman

In brief

If you’ve ever struggled with a rounded Allen bolt, this video shows eight practical ways to tackle the problem—from simple tricks like cleaning the head or using a high-quality Allen key to more involved methods like drilling or welding. It’s aimed at anyone who works with hardware and needs reliable solutions for stubborn bolts.

Key steps

  1. Clean out dirt and debris from the bolt head with care
  2. Insert a good-quality Allen key and try turning gently
  3. Use pliers or a vice grip to grip and shock the bolt loose
  4. Chisel the bolt head carefully with a hammer if needed
  5. Weld a nut onto the rounded bolt for easier removal
  6. Drill the bolt head or use a left-handed drill bit to reverse it

Questions & answers

Do I need special tools for any of these techniques?

Yes—some methods require a screw extractor, welding equipment, or a left-handed drill bit.

Chapters

Description from the creator

In this video I demonstrate some of the techniques that we use regularly on site to remove rounded Allen head bolts, or hex key head bolts. Allen head bolts can be difficult to remove as dirt can get compressed into the head which means the minute you insert the Allen key and apply pressure it rounds off the bolt.
The techniques used in this video are-

00:00 Types of Allen head bolt/screw
00:51 clean out the head
01:22 Use a good quality Allen key
02:26 Shock the bolt/screw
02:41 Apply heat
03:28 Spray penetrant
03:40 Mole grip or vice grip pliers
04:48 Cold chisel and hammer
05:37 Weld a nut onto the rounded bolt
06:01 Drill using a left-handed drill bit
06:55 Drill the head from the bolt
08:42 Screw extractor
10:16 Trend Grab-It pro
10:52 Centre punch

About this tutorial

Ultimate Handyman published this 13:47 video tutorial on October 25, 2018. It has been watched 4,186,386 times on YouTube.

Duration
13:47
Published
October 25, 2018
Views
4,186,386
Likes
35,867

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