Cutting a slot in an Allen Head bolt?

[GCCK]

OK, I'm trying to re-bond my driver side window back into the winding mechanism and first step is to get the door panel out. I'm in S1, btw.

 

Trouble is, to get door panel out, I have to remove window winder handle. First four allen bolts (the visible ones) came out OK, so the lever bit came away no probs. That exposed the centre hub with a recessed allen headed bolt. Except that the allen headed bolt is completely rounded out (methinks: someones been in here before...).

 

I figure the best way to get it out is to cut a slot i the head and tackle it with a screwdriver. If that is the best plan, my question is: what tool would you recommend for cutting a screwdriver-width slot in a slightly recessed bolt head?

 

Any suggestions from some of you practical types would be much appreciated.

Ta

Graeme

[Wuddie]

hmm thats a difficult one as you won't be able to get a hack saw in there, Either you could try and use a dremel type device...or get a slight larger Flat Blad screwdriver for the hold and try to use that to maybe catch in the hole and turn it!...or the last and most drastic..drill out the screw.

[steve]

just a thought but you could try getting some mighty "araldite" and gluing the allen key in there. When completely set, hopefully should bring out the bolt and the only cost is a new bolt (which you need anyway) and a new allen key.

 

If that fails then youre no worse off than before!

 

Good luck

 

steve

[GCCK]

Ahh, closure!

 

After nobody in the area hiring out dremels, eventually took Elise to local garage man. First he attacked the bolt head with a rotary file (to weaken it) and then thumped it the edge at an angle with a hammer & punch to rotate the bolt.

 

Interestingly enough, this chap is considering a proposition I made to him a few months ago: if there's enough interest locally (to Hinckley), he'd like to become an Elise specialist. He's ex-Rover main dealer chief mechanic, has experience of K-series performance tuning and is a switched on, instinctive mechanic (rather than a go-through-the -motions type). And he's not expensive. Been doing my family's cars for 3-4 years now and never messed up, even slightly.

 

I've offered to lend my S1 as his "project" vehicle, plus provide copies of the workshop manual & parts catalogue. I need one or two tuning tweaks + an MoT in the next few months, to get him going.

 

Is there anyone around Cov/Leics/Rugby etc interested in a local specialist?

 

Graeme

[steve]

Definitely!

 

I live in rugby and am taking my car to Bruce tomorrow. i'm sure bruce is great but he lives in a very selfish place!!!

 

If he could do the clutch pipe very soon, then he could have a job from me! it would be nice to have a "bruce" nearby!

 

can you keep me informed?

 

cheers

 

steve

[Black Swan]

I'll say yes on this one too, don't know Bruce, unless he is one of the Monty Python Bruces, who I suspect did not fix Elises.

 

Peter

[steve]

Any news on the new local specialist, Graeme?????