Quick Answer: How do you remove a stripped Allen bolt?
To remove a stripped or rounded Allen (hex) bolt, place a wide rubber band over the bolt head before inserting your hex key to provide extra grip. If that fails, gently hammer a slightly larger Torx bit into the rounded socket, or use a dedicated screw extractor tool to reverse the damaged bolt out of its thread.
Why Do Allen Bolts Round Off?
Nothing brings a DIY or mechanical project to a halt faster than a stripped hex bolt. This usually happens for three reasons: using the wrong size key (such as using a metric key in an imperial fastener), using worn-out, low-quality tools, or applying too much torque. When the internal flats wear away, your Allen key simply spins in place.
3 Proven Methods for Removing a Stripped Hex Bolt
1. The Rubber Band Trick (For minor damage) If the bolt is only slightly rounded, lay a thick piece of rubber (like a wide rubber band or piece of balloon) flat across the top of the bolt head. Push your hex key firmly into the socket through the rubber. The rubber fills the gaps and often provides just enough friction to turn the fastener.
2. The Torx Key Hack (For moderate damage) Because Torx keys have a six-pointed star shape, they can often bite into the rounded corners of a stripped hex socket. Find a Torx key that is slightly larger than the rounded hole. Gently tap it into the bolt head with a hammer until it sits firmly, then slowly turn it anti-clockwise.
3. Use a Screw Extractor (For severe damage) If the socket is completely circular, a screw extractor is your best bet. Drill a small pilot hole into the centre of the bolt, insert the extractor, and turn it anti-clockwise. As you turn, the extractor's reverse threads will bite into the metal and pull the stubborn bolt free.
To prevent this from happening in the future, always ensure you are using high-quality, precision-machined hex keys like the ones we stock at HemBorta.
