Broken allen wrench removal
 

A friend of mine (really!) went to remove a mirror
from his motorcycle. The mirror mount is steel and
mounts to the front brake master cylinder (aluminum).
There is a recess in the mirror into which an allen
head bolt holds the mirror to the master cylinder.
He broke the allen wrench flush to the top of the
bolt. The head of the bolt is recessed to where
you can't get at the sides of it. The bottom
of the bolt is visible on the underside of the
master cylinder.

The only way I can think of to fix this is to
take the master cylinder off, turn it upside down.
Then drill through the bolt from the bottom side.
Then take a punch and knock out the allen wrench.
Then use an impact to take the bolt out.
We'd have to fill the master cylinder full first
so air doesn't get into the line when flipping
it over.

This sounds like a lot of work. Anyone have any
easier suggestions?

His original problem is the mirror keeps loosening
up on the 'stalk'. The ball on the 'stalk' is ridged.
That sits in a plastic piece. By moving the mirror
you can see where the plastic is falling apart in
the ridges. He's already replaced the mirror several
times. Is there any kind of goop that could be put
in there which would hold the mirror, but still
allow movement?

Wayne D.

Broken allen wrench removal
 

Wayne wrote:

A friend of mine (really!) went to remove a mirror
from his motorcycle. The mirror mount is steel and
mounts to the front brake master cylinder (aluminum).
There is a recess in the mirror into which an allen
head bolt holds the mirror to the master cylinder.
He broke the allen wrench flush to the top of the
bolt. The head of the bolt is recessed to where
you can't get at the sides of it. The bottom
of the bolt is visible on the underside of the
master cylinder.

The only way I can think of to fix this is to
take the master cylinder off, turn it upside down.
Then drill through the bolt from the bottom side.
Then take a punch and knock out the allen wrench.
Then use an impact to take the bolt out.
We'd have to fill the master cylinder full first
so air doesn't get into the line when flipping
it over.

This sounds like a lot of work. Anyone have any
easier suggestions?

His original problem is the mirror keeps loosening
up on the 'stalk'. The ball on the 'stalk' is ridged.
That sits in a plastic piece. By moving the mirror
you can see where the plastic is falling apart in
the ridges. He's already replaced the mirror several
times. Is there any kind of goop that could be put
in there which would hold the mirror, but still
allow movement?

Wayne D.

I don't see where you have anything to lose by trying your favorite real
penetrating oil, a couple of gentle heat cycles, a left-handed drill bit from
the top (or remove the master cylinder and use a RH drill from the bottom) and
try an easy-out.

Another trick I like is to make a little square of sheet metal about the size of
a postage stamp, punch a hole in the center, and plug weld it to the end of the
bolt (using O/A or MIG or however you can) then welding a nut to the sheet metal
and using the nut to turn out the bolt. Might be tricky with the seals in the
master cylinder so close, though.

Steel bolts frozen to aluminum can be very tough indeed. My guess is you'll wind
up using a helicoil or equivalent, or maybe buying a new master cylinder.

My guess is this motorcycle isn't a BMW.

GWE

Broken allen wrench removal
 

If it was the proper size Allen, it will come loose with a couple of taps
back, the opposite direction from which it broke, if it was a SAE jammed
into a Metric bolt, good luck. If it snapped and didn't twist, it going to
be hard.
Good Luck
gary


"Wayne" wrote in message
...
A friend of mine (really!) went to remove a mirror
from his motorcycle. The mirror mount is steel and
mounts to the front brake master cylinder (aluminum).
There is a recess in the mirror into which an allen
head bolt holds the mirror to the master cylinder.
He broke the allen wrench flush to the top of the
bolt. The head of the bolt is recessed to where
you can't get at the sides of it. The bottom
of the bolt is visible on the underside of the
master cylinder.

The only way I can think of to fix this is to
take the master cylinder off, turn it upside down.
Then drill through the bolt from the bottom side.
Then take a punch and knock out the allen wrench.
Then use an impact to take the bolt out.
We'd have to fill the master cylinder full first
so air doesn't get into the line when flipping
it over.

This sounds like a lot of work. Anyone have any
easier suggestions?

His original problem is the mirror keeps loosening
up on the 'stalk'. The ball on the 'stalk' is ridged.
That sits in a plastic piece. By moving the mirror
you can see where the plastic is falling apart in
the ridges. He's already replaced the mirror several
times. Is there any kind of goop that could be put
in there which would hold the mirror, but still
allow movement?

Wayne D.

Broken allen wrench removal
 

On Tue, 11 Apr 2006 17:13:39 -0500, Wayne
wrote:

A friend of mine (really!) went to remove a mirror
from his motorcycle. The mirror mount is steel and
mounts to the front brake master cylinder (aluminum).
There is a recess in the mirror into which an allen
head bolt holds the mirror to the master cylinder.
He broke the allen wrench flush to the top of the
bolt. The head of the bolt is recessed to where
you can't get at the sides of it. The bottom
of the bolt is visible on the underside of the
master cylinder.

The only way I can think of to fix this is to
take the master cylinder off, turn it upside down.
Then drill through the bolt from the bottom side.
Then take a punch and knock out the allen wrench.
Then use an impact to take the bolt out.
We'd have to fill the master cylinder full first
so air doesn't get into the line when flipping
it over.

This sounds like a lot of work. Anyone have any
easier suggestions?

His original problem is the mirror keeps loosening
up on the 'stalk'. The ball on the 'stalk' is ridged.
That sits in a plastic piece. By moving the mirror
you can see where the plastic is falling apart in
the ridges. He's already replaced the mirror several
times. Is there any kind of goop that could be put
in there which would hold the mirror, but still
allow movement?

Wayne D.
As far as the wrench goes I can think of two things. First, use a
punch to mark the center of the wrench. Banging on it may loosen it.
After using the punch drill a hole that's the tap drill size for a
thread size smaller than the wrench, but not by much. Tap the wrench
stub. Even though the wrench stub is hard, a tap is harder. The
tapping process will probably loosen the wrench stub if the drilling
doesn't. Or, after drilling the hole, use an impact screwdriver with a
phillips bit in the hole. Impact screwdrivers, the kind you hit with a
hammer, can be had pretty cheap, like 10 bucks. If you already have
the impact wrench, and it sounds from your post that you do, then
you're set. Before using the impact wrench on the screw itself maybe a
little oil and heat could be used first. I think drilling from the
back side is way too much work. I bet that wrench stub pops out when
you start to work on it.
ERS

Broken allen wrench removal
 

In article , Wayne says...

times. Is there any kind of goop that could be put
in there which would hold the mirror, but still
allow movement?

Yes. A Napolean bar end mirror. Throw the stock
ones away.

Jim


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Broken allen wrench removal
 

Oops, I didn't notice it's the wrench and not the bolt that sheared. In that
case, I suggest you drill a hole down the center of the top of the wrench, tap
it, and run a long screw through it to bear on the bolt and push out the wrench
stub. Or just freeze a welding rod to it and pull.

GWE

Wayne wrote:

A friend of mine (really!) went to remove a mirror
from his motorcycle. The mirror mount is steel and
mounts to the front brake master cylinder (aluminum).
There is a recess in the mirror into which an allen
head bolt holds the mirror to the master cylinder.
He broke the allen wrench flush to the top of the
bolt. The head of the bolt is recessed to where
you can't get at the sides of it. The bottom
of the bolt is visible on the underside of the
master cylinder.

The only way I can think of to fix this is to
take the master cylinder off, turn it upside down.
Then drill through the bolt from the bottom side.
Then take a punch and knock out the allen wrench.
Then use an impact to take the bolt out.
We'd have to fill the master cylinder full first
so air doesn't get into the line when flipping
it over.

This sounds like a lot of work. Anyone have any
easier suggestions?

His original problem is the mirror keeps loosening
up on the 'stalk'. The ball on the 'stalk' is ridged.
That sits in a plastic piece. By moving the mirror
you can see where the plastic is falling apart in
the ridges. He's already replaced the mirror several
times. Is there any kind of goop that could be put
in there which would hold the mirror, but still
allow movement?

Wayne D.

Broken allen wrench removal
 

HOw about penetrating oil and a BIG magnet the allen key SHOULD be a
magnetic family of steel right?

On Tue, 11 Apr 2006 17:13:39 -0500, Wayne
wrote:

A friend of mine (really!) went to remove a mirror
from his motorcycle. The mirror mount is steel and
mounts to the front brake master cylinder (aluminum).
There is a recess in the mirror into which an allen
head bolt holds the mirror to the master cylinder.
He broke the allen wrench flush to the top of the
bolt. The head of the bolt is recessed to where
you can't get at the sides of it. The bottom
of the bolt is visible on the underside of the
master cylinder.

The only way I can think of to fix this is to
take the master cylinder off, turn it upside down.
Then drill through the bolt from the bottom side.
Then take a punch and knock out the allen wrench.
Then use an impact to take the bolt out.
We'd have to fill the master cylinder full first
so air doesn't get into the line when flipping
it over.

This sounds like a lot of work. Anyone have any
easier suggestions?

His original problem is the mirror keeps loosening
up on the 'stalk'. The ball on the 'stalk' is ridged.
That sits in a plastic piece. By moving the mirror
you can see where the plastic is falling apart in
the ridges. He's already replaced the mirror several
times. Is there any kind of goop that could be put
in there which would hold the mirror, but still
allow movement?

Wayne D.

Broken allen wrench removal
 

Wayne wrote:
A friend of mine (really!) went to remove a mirror
from his motorcycle. The mirror mount is steel and
mounts to the front brake master cylinder (aluminum).
There is a recess in the mirror into which an allen
head bolt holds the mirror to the master cylinder.
He broke the allen wrench flush to the top of the
bolt. The head of the bolt is recessed to where
you can't get at the sides of it. The bottom
of the bolt is visible on the underside of the
master cylinder.

The only way I can think of to fix this is to
take the master cylinder off, turn it upside down.
Then drill through the bolt from the bottom side.
Then take a punch and knock out the allen wrench.
Then use an impact to take the bolt out.
We'd have to fill the master cylinder full first
so air doesn't get into the line when flipping
it over.

This sounds like a lot of work. Anyone have any
easier suggestions?

His original problem is the mirror keeps loosening
up on the 'stalk'. The ball on the 'stalk' is ridged.
That sits in a plastic piece. By moving the mirror
you can see where the plastic is falling apart in
the ridges. He's already replaced the mirror several
times. Is there any kind of goop that could be put
in there which would hold the mirror, but still
allow movement?

Wayne D.

If you are able to drill the Allen wrench, you might be able to get it
out by packing the hole with grease, inserting a close fitting pin
punch, and hitting it with a hammer.

John Martin