regfman

I'm trying to change out stock handle bars on my dahon D7. The GripShift handle appears to need be unloosened with a set screw. Needs a 2.5 size hex driver. I'm traveling and away from decent tools so I bought foldout set of Husky hex wrenched and I've tried to twist it and the walls of the set screw socket head are not holding up. I've had decent luck on mildly worn socket heads using a high quality hex driver but I don't have access to one. Any ideas how I can extract this screw?

- maybe use the flame from a cigarette lighter to heat the screw and hopefully not melt the plastic?
- drill it out?

cxwrench

How on earth are you going to heat the screw but not melt the plastic? That's one of the more ridiculous things I've read on BF. You might be able to drill it out. Take it to a good bike shop and pay them to do it.

TPL

Screw extractor ....a small one

frogman

I second the screw extractor.

frogman

Please try to limit yourself to just offering constructive comments with out the sarcastic digs..................................

JohnDThompson 

Epoxy a sacrificial Allen key to the bolt and use it to remove the bolt.

cxwrench

I did, I guess you missed that part.

Bmach

Maybe a needle nose vise grip.

frogman

I didn't miss your constructive comment. Very nice.
Did you miiss the part where I asked if you could omit the sarcastic digs ?

masonv45

Hammer in a torx bit and use it to twist out the bolt.

dedhed

This is the "go to" before drilling anything

Rick

First don't ever leave home without proper tools. I only use whia or same quality hex tools. If the torx and epoxy method fail then drilling may be necessary. Carefully drilling so the hex head falls off then center popping The remaining part of the screw and using a left hand drill may work. Finding proper tools on the road is not likely.

regfman

Followup: Yeah, the heating idea is stupid. I admit it, and I didn't do that.
I'm in the process of setting up a second residence and I have a few extra bikes so I shipped them out for me and my wife. I shipped a couple of the redundant general tools I have but I didn't ship my decent Wiha wrenches that probably wouldn't have had a problem with this. I like the idea about using a torx driver but I didn't have one of those with me either.

I took the suggestion to buy a screw extractor bit for $2.89 and I did have a small adjustable wrench to grab it and turn it -- and that worked great. I heard the loctite make that satisfying snap sound and the screw just backed out.

Unfortunately I don't yet have a way to get that screw extractor to release from the screw ....... so I took another trip to the hardware and bought an M5 set screw and the job is done.

sweeks

Clamp the screw extractor in a vise, then use a pair of pliers to grab the screw and turn it clock-wise. But don't re-use the screw.

sweeks

Do you really have to actually *sacrifice* the Allen key? Once the screw is out, it should be fairly easy to knock the screw off. The epoxy should chip off; if not, a file would do it.

JohnDThompson 

Sure. I'd still use a cheap Allen key rather than, say, a Snap-On.

sweeks

Completely agree!

bikemike73 

Glad it all worked out for you.

The method is similar to an " easy out" tool from a stripped screw.

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