Stripped Torx Screw Head

[welike45acp]

Recently picked up a 1999 75D Compact that’s need a thorough cleaning and noticed that one of the torx screws on the aftermarket grips has the star pattern basically stripped/rounded out. The one side I was able to remove but it was almost frozen in there and I figure the other side with the rounded head is probably just as tight and the reason the head is rounded. I will be putting some WD40 on the inside of the grip frame to hopefully penetrate and loosen.

The question is - what is the best way to try and remove the damaged torx screw? Do I try to cut a slot in the head and used a regular screwdriver or is there another way. Cutting a slot with a dremel will probably damage the aftermarket grip which I could live with.


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[no.vale.la.pena]

One thing I have tried with success on stripped torx screw is finding a torx key (that you don't particularly care about) that is oversized for the actual size of the bit and hammer it into the screw. You can also do this, although less effectively, with an oversized hex key.

It may be over loc-tited as well so I would heat-up the screw/frame as well, even just a hair dryer and a few minutes of direct heat will help there.   

[welike45acp]

One thing I have tried with success on stripped torx screw is finding a torx key (that you don't particularly care about) that is oversized for the actual size of the bit and hammer it into the screw. You can also do this, although less effectively, with an oversized hex key.

It may be over loc-tited as well so I would heat-up the screw/frame as well, even just a hair dryer and a few minutes of direct heat will help there.   

Thanks for the ideas


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[Wobbly]

I usually do it 1 of 2 ways....
• Using a very hard and sharp center punch, punch a divot off to the side of the head, then chase that around in a counter-clockwise direction with taps from a small hammer. The screw usually loosens within a quarter turn.

• If the screw is soft enough to wallow out, then it is also soft enough to drill. Measure the dia of the screw thread, and choose a sharp drill bit ever so slightly larger. Place the drill bit into the wallowed out Torx pocket and start drilling straight in. The screw head will fall off soon, which releases the grip. When the grip is removed, the shank will be standing proud where it can be removed with pliers.

[welike45acp]

I usually do it 1 of 2 ways....
• Using a very hard and sharp center punch, punch a divot off to the side of the head, then chase that around in a counter-clockwise direction with taps from a small hammer. The screw usually loosens within a quarter turn.

• If the screw is soft enough to wallow out, then it is also soft enough to drill. Measure the dia of the screw thread, and choose a sharp drill bit ever so slightly larger. Place the drill bit into the wallowed out Torx pocket and start drilling straight in. The screw head will fall off soon, which releases the grip. When the grip is removed, the shank will be standing proud where it can be removed with pliers.

Thank you, some excellent ideas


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[Wobbly]

Hope that works for you. I was a pro motorcycle mechanic for years, and invariably I would need to remove one buggered case screw per day.

[WW Martin]

I've used an easy-0ut to remove them. You may need to grind the tip to get a proper fit. I used to bring the used ones home from work instead of throwing them away.

Bill

[welike45acp]

I've used an easy-0ut to remove them. You may need to grind the tip to get a proper fit. I used to bring the used ones home from work instead of throwing them away.

Bill

Thanks for the idea, need to see if I gone one to fit


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[RSR]

I've used an easy-0ut to remove them. You may need to grind the tip to get a proper fit. I used to bring the used ones home from work instead of throwing them away.

Bill

Thanks for the idea, need to see if I gone one to fit


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Other ideas above are better.  EZ-Outs tend to break and when they do, you're in a bad place as hardened steel...

Either use professional screw extractor sets, or the above ideas.  A slot would work too, but effectively the same as wobblys and you'd go to his if slot is ineffective. 

And a little torch or even lighter heat defeats most locktite...

[welike45acp]

I was able to remove the screw by using the next size bigger Torx bit and tap it into the worn head and slowly unscrewing it. Thanks for all the  ideas and help


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[Ron IL]

Good that you got it out pretty easily.  What we did at work was use left handed drill bits.  We had one that broke a lot was a 1/2" motor mount bolt that would break off.  It was a pretty long task to remove the mount to get to the bolt so we drilled a hole in the bolt and then use a slightly larger left hand bit in it and would grab the bolt and unscrew it out.  I don't like torx screws at all.  I always change them out to slotted screws on grips.  People use hex wrenches on those and ruin them.  I use a magnifier glass to see what they are before I try it.  A quick glance you might think they are hex and not torx.